Revolutionary Polartec Fabrics for Outdoor Enthusiasts

Frigidaire.

Kleenex.

Polartec.

All branded products that eventually became the generic term for their associated product.

If you never looked at the fabric tags for some of your favorite outdoor apparel, you’d probably assume that Polartec was nothing more than that stalwart fleece jacket that you pull out of the back of the closet when leaves start to turn to the yellows, oranges and reds of fall.

More Than Fleece

But there’s a lot more to Polartec than fleece.

Our sister site Bike World News recently had an article about some of the (unexpected) technologies that have made their way into cycling clothing, but in the outdoor market, there is even more to explore in new fabric tech.

AirCore™

Driven by the belief that perspiration impacts performance long before precipitation, Polartec® AirCore™ was developed to offer protection against the elements while allowing vaporized sweat to escape using air and molecular diffusion. Delivering maximum aeration and breathability without sacrificing comfort, range of motion, or durability, Polartec® AirCore™ minimizes the risk of overheating during high aerobic activities or intense physical pursuits in unpredictable conditions. 

AirCore™ made its debut in the sports and outdoor market in cycling jackets from Castelli and Sportful, but I’m sure that the benefits of the technology will attract other outdoor manufacturers to explore and exploit its capabilities.

Power Wool^™

Polartec^® Power Wool^™ combines the classic comfort and thermoregulation of wool with the base-layer fabric performance of advanced synthetic fibers. The proprietary bi-component knit in Power Wool^™ is a one-of-a-kind highly breathable and naturally odor reducing fabric.

If you’ve spent any time in the outdoors, you’ll know that wool is the ur-performance textile. It naturally resists odor, regulates heat, and manages moisture, all of which make it ideal for use in a base layer. Some of my favorite tees are made from a wool blend, and I wear them all year long.

That said, wool also has a few negatives: it dries slowly, is prone to shrinkage, and lacks durability (though that issue is reduced when blended with other fabrics).

Polartec^® Power Wool^™ employs a synthetic face yarn to correct for these deficiencies. The end result is a bi-component fabric that does everything well. Unlike traditional wool fabrics, Polartec^® Power Wool^™ leverages a bi-component knit technology to provide superior durability, moisture wicking, and shape retention, while maintaining the natural softness, breathability, and thermoregulation of the natural wool fibers. The combination of fabrics make it an ideal base layer, but it can also be used for mid-layers and apparel designed for outdoor activities, travel, and multi-day adventures, where both comfort and durability are essential.

To date, it has shown up in underwear, hoodies, and long sleeve base layers.

Power Air^™

Polartec^® Power Air^™ is a revolutionary knit fabric that encapsulates air within a smooth shell to deliver reliable insulation and optimal warmth while reducing microfiber shedding and pollution.

We’ve all likely heard about the prevalence of microplastics in the water, air, and even our bloodstream. Power Air^™ aims to reduce this microfiber shedding by encapsulating the insulating fibers, the ones most likely to shed, within its construction to protecting them from breakage and loss. This not only improves the fabric durability but also helps to lower environmental impact.

But how does it perform? Power Air^™ uses air encapsulation to create thermal insulation without the need for heavy, bulky materials. This means you get the warmth you need while maintaining comfort and freedom of movement, all in a lightweight design. By creating thermal pockets that maintain warmth without the added weight, the advanced design allows for a lightweight yet highly effective insulation fabric that performs over time.

While providing plenty of warmth on its own, Power Air^™ is thin enough to layer with other apparel, expanding its value and versatility.

A great example of Power Air^™ fabric in application is the Houdini Sportswear Mono Air Houdi. This lightweight hoodie can be a four-season piece. The light, stretchy and durable fabric works perfectly as an outer layer in the shoulder seasons, or as insulation underneath a ski jacket or a winter coat when temps drop.

The Mono Air Houdi has been field tested for ski touring, rock climbing, alpine trekking, and many other demanding adventures. The knitted face fabric takes the worst edge of the wind but is still highly breathable. The high collar, snug hood and thumb loops create extra comfort and a sense of being sheltered.

Wind Pro^™

Polartec Wind Pro^™ probably looks closest to the classic Polartec fleece that everyone thinks of when they hear the brand name. But Wind Pro is not your father’s fleece jacket. Wind Pro^™ uses a tighter knit construction than Polartec’s classic fleece, reducing wind chill while retaining high breathability and comfort.

Not only does it provide up to 4x greater wind resistance than regular synthetic fleece, but it also repels light rain and snow. Wind Pro^™ also achieves its wind protection without using film or laminating multiple fabrics, ensuring unrestricted breathability for maximum comfort.

While you’ll often find Wind Pro being used in smaller items like hats and gaiters, Vouri crafted their Aspen Shirt Jacket from the fabric. Crafted like a shirt but built like a jacket, it’s great for hiking, camping, traveling and chilling.

Reviewers praise the jacket for its light weight, softness and cozy warmth without extra bulk.

Power Dry^™

My “go-to” gym shirt is a Polartec^® Power Dry^™ tee, but even beyond the gym, it makes for an excellent all-weather base layer, that quickly wicks moisture away from my skin to the outer layers during activity.

Power Dry^™ uses a bi-component knit technology. This means that it utilizes two different types of yarns with different surface areas to create more space for water uptake on the outside of the fabric – which ultimately acts as a siphon to transport moisture away from the skin. Using complementary mechanisms of fiber orientation, capillary action and hydrophilic enhancements, sweat moves off your body to the outside of the fabric, making it a perfect base layer.

As such, Power Dry^™ can serve as an all-weather base layer. In warm conditions, it keeps you dry and cool, while in cold environments, it efficiently wicks away sweat to prevent chills.

Beyond its use as a simple base layer, Mammut used Power Dry in conjunction with other fabric technologies, in their Eiger Nordwand Advanced ML Jackets and Hoodies.

While the majority of the construction is in Polartec Power Stretch Pro, Power Dry shows up in high sweat in the armpits and the back to keep sweat off the body in cold conditions.

Adding to its versatility, the fabric is also available in flame resistant and rip-stop versions.

Power Grid^™

Polartec^® Power Grid^™ is a lightweight fleece base layer designed to optimize and regulate body temperature. The proprietary grid fabric construction bi-component knit wicks away moisture and transfers it to outer layers for fast evaporation. It’s grid design creates open air channels to increase breathability and reduce bulk, while enhancing thermoregulation.

The bi-component knit technology of Polartec^® Power Dry^™ uses two different types of yarns in a single fabric structure. The yarns have different surface areas to create more space for water uptake on the outside of the fabric which acts as a siphon to transport moisture away from the skin. This allows Power Dry^™ to maximize moisture transfer to ensure rapid evaporation, enhanced breathability and quick-drying performance.

The grid fleece design of Polartec^® Power Grid^™ creates open air channels that trap heat when needed and release excess warmth during activity. This dynamic thermoregulation ensures consistent comfort in changing conditions. The bi-component knit wicks moisture away from the skin and spreads it across the outer surface for fast evaporation, preventing saturation and keeping you dry during movement. The innovative grid construction of Polartec^® Power Grid^™ contains discreet areas of higher loft with voids in between, creating increased airflow in and around the fabric. Travelling via these airflows, body moisture vapor is quickly transported away for exceptional breathability.

Power Grid^™ is ideal for base layers, mid-layers, and activewear designed for outdoor activities, high-performance sports, and cold-weather adventures.

The R1 Fleece Pullover from Patagonia is a perfect example of how outdoor manufacturers have utilized Power Grid^™ fleece. Light and packable, the hybridized R1® Pullover is a versatile midlayer for cool days in the mountains and everything in between.

Polartec^® Delta^™

One usually thinks of Polartec and warmth, but Polartec^® Delta^™ works with the body’s natural cooling process to disperse perspiration across the skin for efficient cooling when hot. Specialized knit construction using both hydrophobic and hydrophilic yarns gives more advanced wicking control to reduce wet-cling and increase airflow breathability for evaporation to dissipate heat. It enhances natural cooling by optimizing airflow, dispersing moisture, and preventing wet cling and works with the body’s natural cooling process – sweat – to make high-intensity, warm-weather activities more comfortable.

Delta is different than other moisture-wicking fabrics because it is engineered with a dual-yarn construction with hydrophilic fibers that draw sweat away from the skin and hydrophobic fibers that promote fast evaporation. This prevents the damp, clingy fabric feeling while increasing airflow, breathability, and enhances cooling performance. Moreover, Delta^™ has a lightweight feel that delivers an instant cooling sensation even before your perspiration activates its evaporative process. Plus, it has natural odor-reducing properties that help prevent unwanted smells from sweat buildup, making it ideal for high-exertion activities.

Castelli’s Active Cooling Base Layer uses Delta to hold a bit of moisture close to your skin to actively cool you on hot days through evaporative cooling. As seen on this garment, Delta can be printed with dye-sublimination technology for any branding or design.

Polartec^® Alpha^™

Polartec^® Alpha^™ is an innovative active insulation designed to adapt to changing conditions by effectively regulating heat and moisture. Originally developed for the US Special Forces to effortlessly handle the stop & go conditions of active combat, Polartec^® Alpha^™ is available in different lightweight compositions and can be worn as a direct, next-to-skin fabric.

Alpha^™ uses a lofted fiber structure with a mesh core, allowing warm air retention when needed and enhanced airflow during movement. This active thermal-management system prevents overheating and keeps you comfortable in unpredictable environments.

Unlike traditional insulation, which traps heat indiscriminately, Polartec^® Alpha^™ offers dynamic breathability, fast dry times and moisture-resistance. By actively adjusting and automatically responding to your activity level, it keeps you comfortably warm without the risk of overheating. Alpha^™ is also lightweight and packable, making it very easy to pack without damaging its insulation properties. But it is also very durable – its resilient structure maintains warmth and breathability over time, even with repeated use and compression.

It’s perfect for adding an active insulation layer to jackets, mid-layers, and hybrid performance wear. It can also be worn directly next to the skin, and used by fashion brands for its aesthetic appeal. As a result, Polartec^® Alpha^™ is ideal for outdoor sports, hiking, mountaineering, all-weather activities and within the latest fashion trends.

Befitting its versatility, Alpha has found its way into a large number of outdoor apparel items.

Power Shield^™ RPM

Power Shield^™ RPM is a high-stretch, waterproof breathable fabric designed for high-performance activities in wet and windy conditions. Featuring a highly durable non-PFAS coating that repels precipitation and 10,000 mm hydrostatic head to keep external moisture out, Polartec^® Power Shield^™ RPM also delivers industry-leading breathability of 30,000 g/m²/24hrs to help solve one of the biggest problems for competitive outdoor enthusiasts: underperformance due to overheating.

The fabric redefines the idea of unstoppable comfort for highly active users. It delivers exceptional durability, industry-leading breathability and a highly durable non-PFAS coating that repels precipitation to keep external moisture out, letting you stay you stay dry and comfortable without the risk of overheating. At the same time, it has an extremely resilient, windproof membrane that provides excellent protection against strong gusts, making it ideal for high-output activities in unpredictable weather. Furthermore, the fabric is 100% recycled and recyclable, helping reduce impact on the planet.

Power Shield^™ RPM is available in 3-Layer and 2-Layer configurations. Unlike rigid hardshells, Power Shield^™ RPM is a lightweight, softshell fabric that offers enhanced stretch and mobility, allowing for unrestricted movement during intense activities like running, cycling, golfing and hiking.

Power Shield^™ Pro

Finally, there’s Power Shield^™ Pro. This is Polartec’s expedition-grade waterproof technology made for the wet outdoors and mountain conditions. Its highly durable, highly breathable, non-PFAS monolithic membrane provides highly breathable & waterproof protection that stands up to the harshest environments.

Unlike stiff, non-breathable hardshell fabrics, Power Shield^™ Pro is soft and comfortable while providing plenty of stretch, making it an excellent softshell alternative for active use in wet and windy conditions. Nonetheless, it is designed to withstand extreme environments, resisting abrasion, tearing, and prolonged exposure to the elements.

Santini utilized Power Shield Pro to create an all weather cycling jacket unlike anything else on the market.

Designed to offer the fit and lightness of a jersey with the performance of a true jacket, it ensures protection and comfort in all weather conditions.

The slim fit ensures an aerodynamic silhouette, while the double-slider waterproof front zipper allows adjustable ventilation. A reflective band on the shoulders increases visibility in low-light conditions, enhancing safety during winter rides. At the back, a waterproof zippered pocket keeps essentials safe from moisture, while a fabric loop on the collar allows for quick drying.

Far More Than Fleece

Hopefully, you can see that Polartec is far more than your average fleece jacket. From the most extreme heat to the most cold, windy and wet conditions, Polartec has fabrics to meet the needs of every athlete.