AirCore™.

Polartec® AirCore™ is an advanced, highly breathable weather-protection fabric engineered for high-output movement in variable conditions. The industry’s first truly air permeable hydrophobic nanofiber membrane made from a proprietary polymer, Polartec® AirCore™ sets a new standard for weather-resistant yet breathable non-PFAS laminates. Featuring a resilient stretch construction that ensures a full range of movement, the nano-fiber membrane allows controlled airflow so that moisture and vapor can escape from the inside-out, keeping you dry and comfortable while still offering protection from wind and rain. The non-PFAS design also incorporates recycled face and back fabrics.

Polartec® AirCore™ is a non-PFAS 3-layer fabric engineered from two layers of material made with recycled polyester yarns and one layer of a functional membrane. The membrane is produced through a process called electrospinning, where a hydrophobic proprietary polymer is pushed through a needle charged at 20,000 volts. Under pressure, it emits a thin jet of microscopic filaments approximately 100 times smaller than a single human hair. These filaments are collected to form a nanofiber membrane that is water resistant while still allowing air to permeate.

Polartec® AirCore™ delivers exceptional breathability thanks to its nano-fiber membrane, which provides air permeability of approximately 0.4 to 1 CFM (ASTM D737 at 125 Pa) and a moisture vapor transmission rate of over 25,000 g/m²/24 h (JIS L1099, B1). These properties allow sweat and vapor to escape quickly, helping maintain a stable microclimate and thus keeping the wearer dry.

The airflow mechanism actively assists moisture transfer, making Polartec® AirCore™ ideal for high-intensity activities where traditional waterproof shells can trap heat and humidity.

Polartec® AirCore™ is designed to be water-resistant. The nano-fiber membrane repels rain and moisture from the outside while allowing the internal vapor to pass through. The exterior fabric minimum spray rating of 4 (GB/T 4745-2012, ISO 4920-2012, MOD). The combination of the two effectively resists light to moderate rain, with an initial hydrostatic resistance level exceeding 4000 mm (ISO811, modified with mesh restraint).

Polartec® AirCore™ is essentially windproof. Engineered with an air permeability sweet spot of .4 to 1 cfm, it’s engineered to block wind while allowing air circulation to prevent overheating. The non-PFAS laminate construction restricts gust penetration without creating a fully sealed barrier. As a result, it maintains a comfortable balance between protection and ventilation. In cold or changeable conditions, this combination helps prevent wind chill while avoiding the moisture buildup that often occurs with impermeable shells.

Yes. Polartec® AirCore™ allows full mobility during activities that demand flexibility and freedom of motion such as cycling, running, and climbing. The fabric's resilient stretch structure fully adapts to the body’s movement while maintaining its weather protection and structural integrity.

Polartec® AirCore™ is made using non-PFAS materials and incorporates recycled fibers in its face and back layers, both of which help lower environmental impact.

Polartec® AirCore™ is tested for lamination durability in a 24-hour continuous, wet agitation cycle. We call it the “killer wash”. AirCore™ maintains fabric integrity and bond strength throughout the test.

Polartec® AirCore™ performs exceptionally well in cycling, running, mountaineering, and fast hiking, where maintaining dryness and avoiding overheating are more important than full waterproofing. The fabric’s controlled airflow system is designed for high-output aerobic pursuits, or any time moisture control and temperature regulation are critical to keep users dry inside out.

Traditional waterproof membranes often rely on impermeable barriers that can lead to overheating and condensation buildup. Polartec® AirCore™ takes a different approach by allowing measured airflow through its nano-fiber membrane. This active air exchange accelerates the removal of moisture vapor, keeping the inside environment significantly drier and more comfortable during intense physical activity.

Garments made with Polartec® AirCore™ should be washed according to the manufacturer’s instructions using a mild detergent and without fabric softener. The DWR performance will benefit from a quick spin in the dryer at low heat.

Polartec® AirCore™ is engineered to provide the active wind and moisture protection you need in unpredictable conditions. And because it helps block wind gusts while maintaining breathability, Polartec® AirCore™ won’t slow you down during high-output activities.

Yes! Polartec® AirCore™ is designed to deliver resilient stretch performance to ensure a full range of motion, making it perfect for demanding activities like running, cycling, and climbing.

Polartec® AirCore™, made with non-PFAS materials, has recycled back and face layers, reducing the reliance on virgin materials and lowering its environmental impact. Of note, Polartec had removed all PFAS-containing materials well before any mandates, ensuring that all products are now entirely non-PFAS.

Polartec® AirCore™ has the durability to move with you and keep you dry from the inside out, season after season. However, non-PFAS DWR is generally less durable than the so-called “forever chemicals”. Its use is better for our environment but comes at the cost of quicker surface wet-out and loss of performance. Luckily, there are ways to combat this. One is to wash the garment according to the manufacturer's instructions, which include the use of a low temperature tumble dry. If you are still having trouble, we suggest an after-market product like Nikwax to refresh DWR performance.

If you're interested in using Polartec® AirCore™ for your designs or collections, please fill out the form below and our team will contact you with more details. Looking for inspiration for your designs? Check out Products and our Made To Partner stories.