Santini Cycling and Polartec, a Milliken & Company brand, introduce the Aero Race Jersey, a performance cycling garment developed using Polartec Power Dry with recycled carbon material. The jersey reflects ongoing efforts in the active apparel sector to integrate material innovation with performance design.
The Aero Race Jersey is constructed with Polartec Power Dry featuring recycled carbon content derived from captured industrial emissions. The process converts CO2 into polyester-based yarns, which are then used in fabric development. According to Polartec, this approach supports reduced reliance on virgin raw materials while maintaining performance characteristics associated with technical apparel.
The fabric is engineered for moisture management, breathability, and thermoregulation during high-output activity. Polartec noted that the material incorporates a high percentage of recycled carbon-based content and is designed to balance environmental considerations with durability and comfort.
Santini and Polartec collaborated on the garment’s aerodynamic construction. The jersey was developed and refined through wind tunnel testing, with design elements intended to support airflow and reduce drag. Features include a close-to-body fit, textured sleeve construction to influence air movement, and rear paneling designed to adapt to rider positioning.
Additional construction details include lightweight fabric, raw-cut sleeves, and rear storage pockets. The design focuses on functionality for performance cycling applications.
“This development reflects Polartec’s continued exploration of material innovation,” said Ramesh Kesh, SVP of Polartec and Apparel Innovation. “The ability to incorporate captured carbon into performance fabrics represents an evolution in how raw materials are sourced and utilized.”
Karen Beattie, Director of Product Management at Polartec, added that the collaboration demonstrates how material science and garment engineering can be integrated within performance apparel.
Fergus Niland, Creative Director at Santini, said the project focused on aligning fabric innovation with the practical demands of cycling, including fit, comfort, and aerodynamic efficiency.
The Aero Race Jersey represents an early commercial application of Polartec Power Dry with recycled carbon material in cycling apparel.
