Castelli Launched New PFAS-Free Cycling Jacket Line
Cyclists now have access to updated jackets featuring a new electrospun, PFAS-free membrane for improved weather protection.
Updated on Oct. 14, 2026 in Cycling
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Castelli has launched the Perfetto 4, Perfetto Pro, and Gabba Pro jackets, which utilize a new, PFAS-free AirCore fabric technology. These models are designed to enhance thermal regulation and moisture protection for cyclists riding in variable weather conditions.
Why it matters
This update transitions performance gear away from PFAS-based chemicals while addressing specific athlete feedback regarding warmth and breathability. By utilizing new fabric technology, these models aim to maintain water resistance and insulation without the use of traditional per- and polyfluoroalkyl substances.
The new jackets incorporate an electrospun AirCore membrane that provides a hydrostatic pressure score of 5,000mm. The fabric maintains an air permeability of 0.7 cubic feet per minute (CFM) and is produced entirely without the use of PFAS-based chemicals.
The players
Castelli
An Italian cycling apparel manufacturer known for its high-performance weather-resistant gear used by competitive and amateur riders.
Sportful
A technical cycling apparel brand that shares exclusive rights to utilize AirCore technology with Castelli.
The details
The jackets function through an electrospun membrane designed to be semi-air-permeable, allowing for heat and moisture vapor to escape while blocking external elements. The Perfetto 4 uses a heavier 219g fabric for increased insulation, while the Pro models feature a 150g weight for better stretch. Structural additions like redesigned splash tails and metal drainage holes in the pockets draw on construction methods from the Gabba R line to manage water runoff.
Timeline
Castelli launched the new line of cycling jackets on October 14, 2026.
Health Landscape
This launch represents a shift in the cycling apparel industry toward high-performance membranes that replace traditional chemical-based water repellents. These new models extend the structural innovations established by the Gabba R series while prioritizing the elimination of PFAS in technical fabrics.
If you are managing exercise in cold or wet conditions, these jackets may offer an alternative to traditional gear treated with potentially persistent chemical coatings. Discuss your specific thermal needs with a coach or experienced cyclist to determine which fabric weight is appropriate for your typical riding temperature range.
The takeaway
Castelli's new line provides a path for cyclists to utilize PFAS-free performance gear without sacrificing weather protection. Riders should consult the manufacturer's temperature guidelines, which range from 4°C to 14°C, to ensure the selected model matches their local riding environment.
Further reading
For more on optimizing your gear for different climates and conditions, visit our Cycling section.
More information
Find technical specifications and performance details on the Polartec AirCore technology information page.
Source note: This article includes information reported by Bike World News.
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