A whole new Castelli: the Espresso apparel range reviewed

“Um, I think I’m going to need a smaller size.” Never in my nearly 20 years of wearing lycra did I expect to utter these words about a Castelli kit, but here we are.

Castelli, the premium Italian cycling apparel manufacturer, is perhaps most often associated with racing and the high-performance (and skin-tight) apparel required by professionals. I, too, have raced for a couple of teams that relied on Castelli for its kit. The Espresso collection, however, is a side of Castelli I hadn’t seen before.

This kit was designed with the goal of being “the first kit you reach for any time you go to ride and not pinning on a number,” explains Steve Chapin, Director of Brand Strategy at Castelli.

In the design brief, the Castelli team prioritised qualities such as supreme comfort, good aesthetics, and performance.

“It has to perform, including moisture management, great bib straps, right amount of compression, etc,” Chapin says. “Essentially something you put on and don’t think about once during the ride.”

The Espresso Project

In designing the Espresso jersey, Castelli also aimed to solve two issues commonly found in jerseys: the aero/ergonomic ‘hunch’ and sagging pockets.

“We wanted a jersey which fit well in both the aero position and while standing up,” Chapin explains, revealing that designing the jersey’s shoulders alone took many drawings and 12 actual prototypes.

The rear pockets, too, were completely re-engineered, resulting in reducing the vertical stretch by 20% to prevent sagging.

For aesthetics, Castelli did something it had never done before: it reduced its logos and got rid of any patterns.

“We threw our colour playbook out the window,” Chapin says. “And shrunk the scorpion on the front of the jersey smaller than we ever have.”

The Espresso collection consists of jerseys in 10 solid colours for men and 8 solid colours for women. Likewise, the bib shorts are available in 8 solid colours for men and 6 solid colours for women.

The bib shorts may seem simple, but Chapin assures designing them was no easy feat.

“We tested 20 fabrics, with the ultimate goal – and end result – being a pair of bibs which feel great while you’re pulling them on and while riding, move with the body, have great elasticity and compression, have improved strap comfort with wider, more breathable bib straps, a drop-tail for women, a higher waistline for stomach support and comfort, a lengthened inseam, and a new, super comfy, minimal, vertical gripper,” he said.

In short, Castelli hoped to design the kind of kit you grab from the drying rack as soon as it's clean, time and again, no matter what type of ride you're setting out on.

So did they succeed? I've spent the summer wearing this kit to find out.

The Castelli Espresso kit key features:

Bibshorts:

• Castelli-engineered Espresso Doppio fabric comfortable to the skin
• Raw-cut leg ending with silicone gripper
• Stretch mesh bib straps for ventilation and comfort
• Progetto X2 Air Donna chamois
• Drop tail capability for easy bathroom use
• Pocket on rear for added storage
• Reflective tabs for increased visibility
• Weight:181 g
• Tailored fit.
• Price: $179.99 / £160.00

Jersey:

• Castell-engineered Air_O Stretch fabric for breathability, comfort and perfect fit
• Fabric optimised for breathability and aerodynamics
• Raw-cut sleeve endings for comfort
• Three back pockets with a fourth zippered security pocket for valuables
• Full-length YKK® Vislon® zipper with easy-use zipper pull
• Elastic at the waist with silicone to keep the jersey in place
• Reflective tab for added visibility
• Tailored fit
• Weight: 113g
• Price: $129.99 / £125.00

The Ride

I always feel a bit apprehensive when trying on new cycling gear, especially since sizing can vary so much between brands. No one enjoys feeling like they’re being squeezed into a sausage casing, and my past experiences with Castelli were during my racing days, when the goal was a second-skin fit. Several years (and pounds) later, I definitely prioritized comfort over aerodynamics.

The Espresso kit pleasantly surprised me. There was absolutely no "sausage" effect. I even had to size down to achieve the tailored fit Castelli intended with this collection. Castelli has always been known for its "Italian sizing"—very snug, often requiring you to size up— but with the Espresso kit, the sizing seems more generous. So, if you're ordering without trying it on first, I highly recommend checking the size chart.

The Espresso W Bib Short

Once I found the right size, the Espresso W DT bib shorts offered just the right amount of compression without feeling restrictive. They move naturally with the body, striking just the right balance.

The drop-tail feature of the shorts adds convenience but also a bit of slack in the bib straps and waist, giving a roomier feel in the back that I don’t love. While functional, it slightly detracts from the otherwise good fit.

I also found myself a little envious of the men’s version, which features mesh bib straps. The women’s version opts for a wide, solid strap, presumably to accommodate the drop-tail functionality. While comfortable, a mesh strap would offer better breathability—something women so often look for given the layers already in play between a bra, heart rate monitor and, sometimes, base layer.

The fabric of the shorts is soft, with just enough stretch and compression to maintain a form-fitting shape. It makes for a comfortable, don’t-think-about-it-twice short. I was also impressed with the Progetto X2 Air Donna chamois pad. It performed well across a variety of rides—from 20-mile jaunts to 120-mile gravel epics— and in hot, sweaty weather. The pad offers ample support without being overly thick. Breathability is key in warm weather and I found that chamois did a good job wicking moisture away from my skin to prevent chafing and saddle sores from sweat buildup.

There's also a small pocket on the lower back of the shorts, likely intended for a credit card, key, or gel. However, given its location, I rarely use it. In hot weather, anything stored there is bound to get soaked in sweat.

My only real issue with the Espresso bib shorts is durability. After a month or two of regular riding, I noticed the seams starting to fray.

The Espresso W Jersey

The Espresso W jersey is incredibly soft, lightweight and breathable, making it ideal for summer rides. During the heat waves we experienced, it quickly became a frequent choice thanks to its airy feel and freedom of movement. You’ll likely need a vest or jacket for cooler morning starts or during the shoulder seasons, but Castelli’s wide temperature rating of 64°F to 95°F (18°C to 35°C) is spot on.

The main zipper features a pull tab that’s rather large but I like how efficient it is. With these thin and highly stretchy fabrics, there’s not a lot of resistance and pulling the zipper down or up for temperature control becomes a two-hand task at times. The YKK zipper used in the Espresso jersey can be used single-handedly and lays flat (when in the riding position; less so when seated).

The extra attention the designers gave to the jersey's shoulders really shows as well. The fabric lays flat, even in various riding positions, and I particularly like the raw-cut sleeves. Despite lacking grippers, the sleeves stay perfectly in place without curling or unravelling.

One feature I’m less convinced by is the thick elastic band at the front of the jersey hem. It feels a bit bulky, especially since there’s already a lightweight band around the entire hem.

The jersey sports three open pockets and an additional zippered pocket for valuables. There’s an elastic band around the opening of the pockets intended to prevent items from bouncing. As mentioned above, the pockets have less stretch than the material used elsewhere on the jersey to prevent sagging. Still, with jerseys this thin and light, sagging is inevitable, and while there’s ample storage space, I limit my pockets to a light outerlayer, a credit card and a gel or two. Anything heavier gets put inside a small bar bag.

Overall, I’ve been impressed by the jersey in its comfort and style. The minimalistic design is a refreshing change from Castelli’s typical aesthetic. Aside from a small scorpion logo on the front shoulder and another on the rear pocket, the kit maintains a clean, understated look. And with nine colour choices, there’s bound to be one to suit your style.

Value & Verdict

Did Castelli create a kit I grab from my laundry before I have a chance to put it away? It’s pretty darn close. It certainly featured heavily in my rotation this summer and will continue to do so.

It’s not quite as good as my go-tos: Velocio’s Luxe Bibshorts paired with the brand’s Concept SE jersey, but it’s also significantly less expensive: $496 ( £351) for the Velocio kit versus $310 (£285) for the Castelli Espresso kit. It’s cheaper also than a mid-range Rapha or Le Col kit, which will set you back around $350-$400. As such, the Espresso kit is very reasonably priced.

Overall, the Espresso kit combines comfort and the performance Castelli is known for with a smart, minimalistic design that’s a refreshing departure from the brand’s traditional offerings. Despite a few minor drawbacks, the kit delivers on comfort, style and fit – all for a reasonable price.

So if you're seeking a versatile, comfortable everyday kit, the Espresso collection is a strong contender.