Best Men's Down Vests of 2023-2024
The best men's insulated vests for warmth, aerobic activities, and more
September 30th, 2023
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When thru-hiking the Pacific Crest Trail in August, I spent many nights sitting around camp wishing I could trade my puffy jacket for a lighter-weight insulated vest. That puffy jacket was too warm for peak summer conditions, but it got too cold at night to ditch that insulating jacket altogether. An insulated vest would have been perfect, and I’ve been vest-curious ever since.
Now, after wearing many of the best insulated vests for a summer of adventures in Colorado and Wyoming, I’m fully onboard—and so are our other testers. We think insulated vests are the best insulation choice for warm-weather adventures when you still need something for a little extra warmth.
An insulated vest is a great option when it’s not quite cold enough for a jacket, but you still need a little extra warmth. Insulated vests are perfect active layers for cold weather, too. The sleeveless design vents heat much better than a full-on jacket, but the insulation over your core still keeps you warm.
We researched the best insulated vests, then spent weeks running, biking, backpacking, and hiking in the top men’s insulated vest models, from cold alpine summits to chilly fall mornings, to help you find the best insulated vest for your needs.
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COMPARISON TABLE
| MEN'S VEST | TREELINE AWARD | BEST FOR | SIZES | INSULATION | HOOD OPTIONS? | PACKABLE? | WEIGHT | POCKETS | SHELL |
|---|---|---|---|---|---|---|---|---|---|
| Rab Microlight | Best Overall Read why |
Multisport | S-XL | Recycled 700FP Down with Nikwax Hydrophobic Finish | no | yes | 11.2 oz | 2 handwarmer | Pertex Quantum Ripstop |
| Patagonia Down Sweater Vest | Best Trail to Town Read why |
Multisport | XS-XXL | 900-fill Responsible Down 100% virgin goose down | Hooded options available? | yes | 8.9 oz | 2 handwarmer, 1 internal zip chest ocket | NetPlus postconsumer recycled ripstop nylon |
| Montbell Thermawrap | Best Synthetic Read why |
Fast and light, wet conditions | S-XL | EXCELOFT synthetic insulation | No | yes | 7.7 oz | 5 (2 zippered handwarmer, 1 zip chest, 2 internal zip) | 12 D nylon ripstop with DWR |
| Patagonia Nanopuff Vest | Best Aerobic Read why |
Snowsports, casual | XS-3XL | 60 g PrimaLoft Gold Insulation Eco postconsumer recycled polyester | no | yes | 8 oz | 3 (2 handwarmer, 1 internal) | Recycled polyester ripstop |
| Mountain Hardwear Ghost Whisperer 2 Down Vest | Best Lightweight Read why |
Multisport | S-XXL | 800-fill-power goose down | no | yes | 6.28 oz | 2 zippered handwarmer | 10-denier x 10-denier ripstop recycled nylon |
THE WINNERS
BEST OVERALL DOWN VEST: RAB MICROLIGHT DOWN VEST
Weight: 11.2 oz
Available sizes: S-XL
Fit: Regular
Shell fabric: Pertex Quantum Ripstop
Insulation type: Recycled 700FP Down with Nikwax Hydrophobic Finish
What we liked: Very comfortable, recycled down fill, recycled shell, warm, great fit
What could be better: Heavier than some vests
The Rab Microlight Vest is the best down vest overall because it’s comfortable, warm, durable, and looks great. What truly makes this vest stand out is its sustainability, but everything else is great about it too. We tested the Microlight during summer and fall in Colorado, taking it on hikes, runs, and bike rides around town and on the Colorado Front Range. The Rab Microlight outperformed every down and synthetic vest in nearly every criteria we judge for--even surpassing the much praised Patagonia Down Sweater Vest (see more below).
We tested a lot of awesome vests for this guide and nearly chose the Patagonia Down Sweater Vest as the best overall. But, there's a few reasons the Microlight outperforms the Sweater Vest. In this review, we'll explain why.
RAB MICROLIGHT DOWN VEST
The Rab Microlight is the first vest we’ve found that uses recycled down insulation and is still just as comfortable and good-looking as the Down Sweater Vest.
Not only was this vest just as comfortable and good-looking as the Patagonia Down Sweater Vest, but we also noticed the Microlight Vest was more weather resistant, warm, and durable than any other vest we tested.
With the Microlight, you get a more technical vest that looks just as good as the Down Sweater Vest at a lower price. This vest works well on the trail and just as well in town, making it an all-around great choice.
The Microlight Vest is made of soft and durable Pertex Quantum ripstop nylon fabric and 700-fill Nikwax-treated water-resistant down. This ripstop fabric is some of the softest we tested. It’s almost as comfortable as the Patagonia Down Sweater, and feels better against your skin than every other vest we tested. This is the only vest we tested with down treated with PFC-free Nixwax hydrophobic coating, and the Pertex® Quantum ripstop nylon outer material has a weather-resistant DWR coating that blocks wind and light precipitation better than any other vest.
The recycled down used in the Microlight performs just as well, if not better, than any other down vest, including the Down Sweater Vest. We found the Microlight is warmer than the Down Sweater during testing on chilly mornings. The Microlight has different sized baffles in different areas of the vest to optimize warmth. I has wider down baffles on the front, tops of shoulders, and back to accommodate more down, and smaller baffles under the arms where you don’t need quite as much warmth.
Another thing that convinced us to choose the Rab Microlight over the Down Sweater is we also like how the Microlight fits better than the Down Sweater, especially in the armholes. The Microlight Vest’s armholes have less stretch than the Down Sweater, but Down Sweater’s armholes hang farther out over the shoulders in a way that feels more restrictive than the Microlight.
The Microlight hugs the shoulders in a way that feels more comfortable and looks less boxy, while allowing for just as much range of motion. We think the Microlight Vest looks the best, mostly because of how the shoulders fit compared to the Down Sweater Vest. The Down Sweater Vest does look great, too, but the aforementioned shoulder and armhole areas don't fit quite as well as the Microlight.
Like every other vest we tested, It has two zippered hand pockets and an exterior zippered chest pocket large enough for a smartphone. The Microlight also has a very comfortable knit fabric sewn into the inside of the zipper garage to prevent chapping on your chin.
Every piece of Rab gear has a material facts list, which lists the total recycled content and fluorocarbon content of every garment they make. The material facts of the Microlight Vest are laid out clearly in what looks like the nutrition label you see on packaged food. Everything but the zippers and trim is made of recycled materials on the Microlight, for a total recycled content of 91%. This is unique among outdoor brands, and highlights sustainability of the Microlight Vest.
At 11.2 ounces, the Microlight Vest isn’t the lightest. If you’re prioritizing weight, several vests we tested weigh less than this one. A heavier vest is more durable and weather resistant, though, as a slightly thicker shell material is less prone to tearing and will block wind and rain better. This means the Microlight will last longer and keep you warmer, so the heavier weight isn’t necessarily even a downside. Plus, a heavier weight means more down, which makes it that much warmer. And 11 ounces isn’t that heavy, either.
The Microlight Vest has tons of positive customer reviews on Rab’s website. OutdoorGearLab, Advnture, and Feed The Habit also have great things to say about this vest. This vest is extremely comfortable, durable, warm, and weather resistant. And has the most recycled content of any down vest we tested. There are some less expensive insulated vests out there, but the Microlight isn’t the most expensive, either. The Microlight toes the line between technical apparel and good-looking all-around performance, and it will suit your needs for a sustainable insulated vest that will last you for years to come.
BEST DOWN VEST TOWN-TO-TRAIL: PATAGONIA DOWN SWEATER VEST
Weight: 8.9 oz
Available sizes: XS-XXL
Fit: Regular
Shell fabric: NetPlus postconsumer recycled ripstop nylon
Insulation type: 900-fill Responsible Down 100% virgin goose down
What we liked: Very comfortable, warm, recycled shell material, repair patches included, great pockets
What could be better: Expensive
The Patagonia Down Sweater Vest is the best down vest for wearing everywhere, from town to trail. This vest is warm, cozy, looks great, and is versatile enough to wear all day, all winter long. With the Down Sweater Vest, you can go for a chilly morning hike, stop at a coffee shop, go to work, and then grab a drink with your friends without ever taking it off. That’s exactly what we did, anyway.
We tested this vest in Colorado during late summer and fall while hiking, backpacking, camping, biking, and simply wearing it around town. We did just about everything in this vest because it’s suitable to do just about everything. It’s fantastic overall, and we almost picked it as the best overall down vest, but the Rab Microlight fit better in the arms and has recycled down fill.
PATAGONIA DOWN SWEATER VEST
This is one of the warmest vests we’ve worn. On chilly mornings in the Wind River Range, it was warm enough under a windbreaker to keep your core temperature up. And it’s a great addition to a fleece jacket or sweater when it gets even colder. It’s not quite as warm as the generously down-filled Outdoor Research Cold Front, but it’s definitely warmer than the ultralight Mountain Hardwear Ghost Whisperer. The Down Sweater Vest is warm enough to wear often without being too hot, so you often need to take it off.
At 8.9 ounces, it’s light and packable enough to throw in your bag for later. This isn’t quite as light as the featherweight Ghost Whisperer, which weighs a mere 5.1 ounces, but under 9 ounces is light enough for most people.
Warmth and weight aside, the thing we love most about the Down Sweater Vest is that it’s downright comfortable. The lining material is incredibly soft and not slippery like some lightweight insulated vests. The face fabric feels so good on your skin that we’re always running our hands along the face material to confirm that it is truly as comfortable as we remember. And the updated fit on the Down Sweater Vest makes it even more comfortable. Previous versions of this vest didn’t fit quite as well; it was boxy and not great for layering under a rain jacket or with a fleece underneath. But the newest version of this vest fits great, making it that much more comfortable.
The Down Sweater Vest is also one of the more sustainable vests we tested. Its shell materials are made of recycled fishing nets, and its 800-fill down insulation is 100% Responsible Down Standard certified by Control Union. Patagonia’s lifetime warranty is one of the best out there as well. They will repair this vest if anything breaks or tears, and Patagonia even includes a set of stick-on repair patches with every Down Sweater Vest.
Also, we are impressed with the wide range of sizes the Down Sweater Vest is available in. It comes in XXS-3XL, which is some of the widest range of sizes of any vest we tested. If we had an award for inclusive sizing, this would be a top choice for that as well.
The Down Sweater is one of the most expensive vests we tested. If you’re on a budget, there are definitely less expensive options than this vest. However, after you purchase this vest one time, you’ll have it for a long time to come. And Patagonia’s repair and warranty programs are great. Once you purchase this vest, you can keep getting it repaired for the life of the vest, so it will last for life. We think it’s worth the price for this reason.
We also found the arm holes weren’t quite as comfortable as some other vests, mostly the Rab Microlight. The Down Sweater Vest has stretchy material surrounding the arm holes, and this stretchy material squeezes your shoulders ever so slightly. It isn’t bad, and it’s definitely not a deal breaker, but it isn’t the most comfortable in the shoulders.
Nevertheless, the Down Sweater Vest is incredibly popular, and downright ubiquitous in the mountain west. There are hundreds of positive customer reviews online. It wins best down vest on NYT Wirecutter and Switchback Travel both gave this vest high praise as well (full disclosure: Treeline Review editor in chief, Liz Thomas, wrote the NYTimes Wirecutter piece).
The jacket and hoody version of this vest, the Down Sweater Hoody, was our overall winner for best down jacket guide in our Best Down Jackets guide. We liked it so much, we even wrote an in-depth gear review on the Down Sweater Hoody after many years of testing.
We think the Patagonia Down Sweater Vest checks all the boxes we look for in a great vest, so it’s perfect for most people. You can wear this vest anywhere, from the mountains to the office.
BEST OVERALL SYNTHETIC VEST: MONTBELL THERMAWRAP VEST
Weight: 7.7 oz
Available sizes: S-XL
Fit: Standard
Shell fabric: 12 D nylon ripstop with DWR
Insulation type: EXCELOFT synthetic insulation
What we liked: Lightweight, durable, breathable, stretchy materials, comfortable, reversible
What could be better: Included stuff sack is easy to lose, Not made of recycled materials
After summer testing this vest while backpacking, biking, and trail running, we think the Montbell Thermawrap Vest is the best overall synthetic insulated vest. The Thermawrap is a versatile vest with a highly-breathable synthetic insulation that keeps you warm without overheating, so you can stay active and not have to take your vest off when you start working even harder. It’s warm enough to keep you comfortable in summer alpine conditions while lightweight and breathable enough to leave in your pack when needed.
MONTBELL THERMAWRAP VEST
We wore this vest while backpacking in the Wind River Range in Wyoming, where the temperatures were hot during the day but chilly in the mornings and at night. We also wore it while camping in Colorado and Wyoming, on early morning bike rides, and while trail running and peak bagging in Colorado.
The fabric repels wind and light rain, and the synthetic insulation keeps you warm even when wet. The fit is comfortable and doesn't bunch or ride up when you move. The 12-D Ballistic Airtight Nylon ripstop material is highly abrasion-resistant as well. Compared to lightweight puffy vests like the Mountain Hardwear Ghost Whisperer, this vest won’t rip nearly as easily. And if the shell material does rip, synthetic insulation won’t leak out the rip like down.
The hand warmer pockets are big enough to store essentials or keep your hands warm. And the chest pocket is large enough for a smartphone. This lightweight vest compresses into a Nalgene-sized stuff sack when you aren’t wearing it, and you can also skip the stuff sack and simply stuff it into one of the handwarmer pockets. It’s also the most affordable insulated vests that we tested.
While we love almost everything about this vest, it isn’t the most stylish. There are better choices if you’re looking for a vest that you can wear around town or to the office. Also, this vest is still not made of any recycled materials, which seems out of step in a world increasingly full of recycled nylon outdoor gear.
This is a great choice if you’re looking for a cold-weather active layer or breathable insulation for summer backpacking. The Thermawrap vest has lots of positive customer reviews, and NYT Wirecutter also chose this as one of the best insulated vests. The Thermawrap is downright legendary in the backpacking world, and we think the Thermawrap Vest is an excellent choice for anyone looking for an active layer or an ultralight summer backpacking outer layer to use in place of a puffy jacket.
BEST VEST FOR AEROBIC ACTIVITIES: PATAGONIA NANO PUFF VEST
Weight: 8 oz
Available sizes: XS-3XL
Fit: Regular?
Shell fabric: Recycled polyester ripstop
Insulation type: 60 g PrimaLoft Gold Insulation Eco postconsumer recycled polyester
What we liked: Lightweight, breathable, comfortable zipper garage, Recycled content inside and out
What could be better: Not as warm as some vests
The Patagonia Nano Puff Vest is our favorite vest for aerobic activities. This vest is insulated with the highly breathable PrimaLoft® Gold Insulation Eco, which insulates even when wet. This insulation vents heat well, but during high-output activities you’re going to sweat, even when wearing breathable clothing. The Nanopuff will continue to insulate even when it gets wet from your sweat, so you won’t get too cold when you stop moving.
PATAGONIA NANO PUFF VEST
We tested the Nano Puff Vest in Colorado during the summer. We wore it while biking around Denver on bike paths and city streets, wore it while hiking the Colorado Front Range on chilly mornings, and carried it with us throughout the day as an extra layer. We also have a lot of experience wearing the Nano Puff jacket, which is the same as the vest with the addition of sleeves, so we’ve spent a lot of time wearing this synthetic insulation piece from Patagonia.
The Nano Puff vest is thin and lightweight and great for layering under a jacket. Its face material is thin and soft. It has a slightly slippery feel but doesn’t feel sticky as you sweat. It has zippered hand pockets that are exactly where you want them to be and an interior chest pocket that is perfect for storing your smartphone to keep it warm against your chest.
The chest pocket also doubles as a stuff sack, and the vest packs down to about the size of a Nalgene water bottle. It has a small strip of knit material on the interior of the face fabric, which feels comfortable against your chin.
The Nano Puff Vest is pretty similar to the Montbell Thermawrap vest, our top choice for a synthetic insulated vest. The Thermawrap is overall a little more breathable than the Nanopuff, and the Thermawrap shell material feels less slippery than the Nanopuff. But that slipperiness is useful for some situations. For example, we think the Nano Puff works really well as a piece to layer on top of, like you would for skiing, as the fit is a little more trim. On the other hand, the Thermawrap is better worn outside your other layers because the material is slightly more abrasion resistant. Both of these vests are great, though, and are each highly breathable with insulation that insulates even when wet. We also think the Nano Puff works better in casual scenarios, so it’s slightly more versatile.
The Nano Puff, along with the Rab Microlight, is the only other insulated vest that’s stuffed with recycled insulation. The PrimaLoft® Gold Insulation Eco is made of 100% post-consumer recycled polyester with “P.U.R.E” technology (Produced Using Reduced Emissions). The exterior materials on the Nanopuff Vest are also 100% recycled polyester. This vest is also made in a Fair Trade Certified™ factory. Patagonia’s repair program is excellent. They will repair any garment they make for life and only replace damaged or worn out gear as a last resort.
The Nano Puff is downright legendary in the outdoor world, and is very popular in winter sports and summertime activities as well. The Nano Puff Vest has tons of positive customer reviews online, and Switchback Travel named it one of their top picks for an insulated vest. We think this is a great vest for aerobic activities and much more. It looks great, is super comfortable, and breathable enough to keep wearing even when the trail gets steep.
BEST LIGHTWEIGHT INSULATION VEST: MOUNTAIN HARDWEAR GHOST WHISPERER/2 VEST
Weight: 5.1 oz
Available sizes: S-XXL
Fit: Regular?
Shell fabric: 10-denier x 10-denier ripstop recycled nylon
Insulation type: 800-fill-power goose down
What we liked: Ultralight, extremely packable, comfortable
What could be better: Not as durable, expensive
The Mountain Hardwear Ghost Whisperer/2 Vest is the best lightweight insulated vest, hands down. The men’s size small that we tested weighs a mere 5.1 ounces. Yes, you read that right. The Ghost Whisperer is very popular among ultralight backpackers and mountaineers. While it isn’t the most durable, you’ll forget you’re carrying it in your pack until you need the extra warmth.
MOUNTAIN HARDWEAR GHOST WHISPERER/2 VEST
We tested this vest on a summer backpacking trip in Wyoming’s Wind River Range. We also tested it in Colorado while hiking, backpacking, and trail running. It’s small and light enough to carry in a trail running vest, and this vest with a windbreaker is enough to keep you warm for a break at the summit or windy overlook. The jacket version of the Ghost Whisperer is also one of our favorites for colder-weather backpacking. We’ve put in tons of miles with our Ghost Whisperer.
The shell is made of ultra-thin 10D Recycled Nylon ripstop material. It’s stuffed with 800-fill RDS®-certified down insulation. While the shell material isn’t quite as comfortable as the Patagonia Down Sweater or Rab Microlight, it’s surprisingly soft, considering how light the material is. And since this vest is so light, it doesn’t feel like you’re wearing it. It’s super thin, so it’s great to layer on top of. But it gives a surprising amount of warmth considering the thickness.
It has zippered hand pockets with ultralight zippers that never seem to snag. Snagging zippers is the bane of most ultralight gear and can lead to tears in the delicate fabric. The fact that these zippers don’t catch or snag means the vest is less likely to fail here. And the right-hand pocket doubles as a stuff sack. When packed into this pocket, the vest is barely larger than a 500 mL water bottle–half the size of a Nalgene.
Previous versions of the Ghost Whisperer Vest weren’t made with recycled materials. However, the Ghost Whisperer/2 Vest is now made with ultralight and recycled ripstop nylon. Adding recycled material doesn’t add any weight, but it does add a big improvement in sustainability, which we love. All Mountain Hardwear gear also comes with a lifetime warranty, and they’ll attempt to repair any damaged items before replacing them.
This highly lightweight down vest comes at a price, though. The Ghost Whisperer/2 Vest is the most expensive vest we tested. The shell material on the Ghost Whisperer/2 is less durable than all of the heavier vests we tested, too. Our trusty Ghost Whisperer jacket that we use for three-season backpacking has a couple of repair patches on it. You’ll have to be careful with this vest, especially if using it while hiking in brushy locations. But if you’re okay with a few patches on your vest, this will reliably keep you warm when you need it and disappear in your pack whenever you aren’t wearing it.
The Ghost Whisperer/2 Vest has tons of positive customer reviews online, and OutdoorGearLab and Switchback Travel also have good things to say about it. The Ghost Whisperer Jacket revolutionized the ultralight backpacking world when it was first introduced, and it has been a mainstay in thru-hikers’ packs ever since. We think the Ghost Whisperer/2 Vest is a great choice for anyone looking to shed as many ounces as possible from their pack.
BEST INSULATED VEST FOR WINTER: OUTDOOR RESEARCH COLD FRONT
Weight: 16 oz
Available sizes:
Fit: Regular?
Shell fabric: 30-denier Pertex Quantum Eco double-ripstop polyester
Insulation type: 700-fill-power Responsibly Sourced Down
What we liked: Durable, Very warm, comfortable, casual look, knit lined pockets
What could be better: Pretty heavy, not very packable
We think the Outdoor Research Cold Front is a great option if you’re looking for an insulated vest to keep you warm all winter. This vest has the most down of any vest we tested, so it’ll keep you warmer when the temperatures drop. It has a casual look that fits in around town, and it has the feel of a thick winter puffy coat without sleeves, so it’s more versatile than that bulky winter coat. During outdoor activities where it’s cold enough to wear a winter coat but you need more mobility than that big bulky coat provides, such as shoveling snow, downhill skiing, and winter biking, this vest is perfect for keeping your core warm but your arms agile. We tested the Cold Front Vest during summer and early fall in Colorado, wearing it around town and around the campfire at night.
OUTDOOR RESEARCH COLD FRONT
The Outdoor Rsearch Cold Front Vest features heavy-duty 30-denier ripstop shell and lining material. This material is thicker than many of the other insulated vests we tested, so it will stand up to the elements better than a lightweight vest like the Mountain Hardwear Ghost Whisperer on Montbell Thermawrap.
It has two zippered handwarmer pockets and a strip of knit fabric inside the zipper garage for when you zip it up to your chin in frigid temperatures. And, it has the same knit materials inside the pockets, which is oh-so-cozy on your bare hands.
At 16 ounces, the Cold Front weighs as much as three Ghost Whisperer Vests. That’s pretty heavy. And the Cold Front Vest isn’t the most packable, either. This is the only vest we tested that doesn’t have a stuff sack or integrated stuff sack pocket. It’s still relatively packable since it’s a down vest, but it doesn’t disappear in your pack like some insulated vests do.
This vest is also only made with 53% recycled shell and lining materials, which is better than nothing. But this vest lags in sustainability compared to many of the vests we tested here with 100% recycled shell materials.
The Outdoor Research Cold Front is a great vest for winter and offers lots of warmth during warmer months, too.
The Cold Front is a great option for a cold-weather insulated vest to wear every day when weight and packability aren’t as big of a concern. It has many positive reviews online, and we think this is an excellent choice for a winter vest.
BEST AFFORDABLE DOWN VEST: OUTDOOR VITALS NOVAPRO VEST
Weight: 8 oz
Available sizes: S-3X
Fit:
Shell fabric: 20 Denier Nylon with DWR treatment
Insulation type: DownLT blend: DWR treated HyperDry + synthetic loose fill
What we liked: Stitchless baffles are warmer and more protective, longer cut cover waist and back, good fit, comfortable, affordable
What could be better: Ultralight fabric has slippery feel
The Outdoor Vitals NovaPro Vest is a lightweight and extremely weatherproof down-insulated vest, and is the most affordable vest we tested. We think it's a great value considering all the technology that went into this vest.
It features a unique stitchless baffle design that keeps the down in place without the need to sew the fabric. The lightweight fabric has no stitch holes, so it’s more water and wind-resistant. Since there is less stitching to come undone, the NovaPro is more durable than other insulated vests.
OUTDOOR VITALS NOVAPRO VEST
We tested the NovaPro through winter and summer.
We tested the NovaPro in summer in Colorado and Wyoming, while backpacking in the Wind River Range and on hikes on the Colorado Front Range. We also wore the NovaPro jacket all winter this year, taking it backpacking during an early-season snowstorm in Zion National Park and all over Colorado during a cold and snowy winter.
The NovaPro vest is very warm for the weight due to its high fill power insulation mixed with synthetic insulation.
The NovaPro Vest is very warm for the weight. It weighs only 8 ounces, but it has almost as much loft as the warm Outdoor Research Cold Front. The NovaPro has a fill weight of 90 grams, compared to the Cold Front, which has a fill weight of 150 grams, this isn’t nearly as much down. But we found the NovaPro was warmer in high winds than the Cold Front, even though it has less down.
Unlike the sewn baffles on other insulated vests, the stitchless baffles prevent wind from cutting through the fabric, making this lightweight vest warmer than most. It’s also slightly longer than most other vests we tested, which adds extra warmth since the cold can’t cut underneath.
The NovaPro vest packs down into its pockets and is smaller than a Nalgene bottle.
It has two zippered handwarmer pockets and packs into the left pocket. When packed, this vest is larger than a Nalgene water bottle, which is pretty big for a puffy vest. But you can actually compress the vest smaller than the hand pocket/stuff sack’s size if you use a stuff sack other than the one it comes with. So it can pack small enough for space conscious backpackers.
The Outdoor Vitals NovaPro vest has a slippery and shiny finish.
However, the NovaPro isn’t as comfortable as some other insulated vests we tested. The lightweight material is slippery and less soft than some vests, and it feels stickier than some materials when wet. It’s also a high-tech vest, and that stitchless baffle technology isn’t yet available as a recycled material.
The NovaPro vest is covered by Outdoor Vitals’ lifetime warranty, so they’ll repair or replace any item that has manufacturing defects. They also have an in-house repair program for damaged or worn items outside the warranty coverage.
The NovaPro Vest has a lot of positive customer reviews on the Outdoor Vitals website, and GearJunkie has positive things to say about the NovaPro as well. This is a pretty unique insulated vest, and we think it’s a great choice for cold-weather backpacking or an all-around insulating vest that handles wind and precipitation better than other down vests, all at a lower price than most insulated vests.
Other vests worth considering
REI CO-OP 650 DOWN VEST
Weight: 8.1 oz
Available sizes: S-3XL
Fit: standard
Shell fabric: recycled nylon ripstop with DWR
Insulation type: 650-fill down
The REI Co-op 650 Down Vest caught our eye because it’s incredibly affordable. This vest is less expensive than any other vest we tested, and it comes in a wide variety of sizes to fit many different body sizes. We're looking forward to testing it and will report back soon.
Weight: 8 oz
Available sizes: XS-3XL
Fit: regular?
Shell fabric: Ripstop nylon
Insulation type: 800-fill-power goose down
The Cotopaxi Fuego Down Vest is another great vest we considered. We love Cotopaxi’s business model and their commitment to sustainability, and we’ve got our eye on this vest. It comes in a bunch of cool color combinations that make it stand out in a sea of solid colored insulated vests. This is also the only vest we’ve seen with two internal stash pockets. It’s an affordable and good-looking option worth considering for a vest that looks great around town and will perform on the trail as well. We're looking forward to testing it and will report back soon.
BUYING ADVICE / WHAT TO LOOK FOR IN AN INSULATED VEST
Close-up on some of the vests we tested.
TYPE OF INSULATION
Insulated vests usually have down or synthetic insulation. Sometimes insulated vests have a combination of both types of insulation, too. For more information on types of insulation, check out our guide to down and synthetic insulation.
DOWN INSULATION
Down is an extremely lightweight, natural insulating material that comes from geese or ducks. It’s the fluffy clusters found under the feathers of ducks, geese, and other birds. If you’ve ever seen a bird floating comfortably on a frigid lake and wondered how is that bird not freezing? The answer is down.
Down traps air, creating pockets of warm air in the baffles of an insulated vest or jacket. It is extremely warm, as you’d expect from the material that allows ducks to float on a mostly frozen lake.
Down-insulated vests have the highest warmth-to-weight ratio of any puffy vests, and they’re also the most packable. Down has a high level of loft, or puffiness, but compresses easily to pack away when you aren’t wearing your vest.
Down has some shortcomings, though. First, down does not insulate when wet. If you’re using a down-insulated vest in rainy conditions or while sweating a lot, you’ll notice the vest doesn’t feel as puffy when wet. When down loses its loft, as it does when wet, a down vest won’t keep you as warm.
Secondly, down is not vegan. And though some down is ethically sourced, not all of it is. If you’re concerned with the ethical treatment of birds, you should consider buying down products certified by the Responsible Down Standard or Global Traceable Down Standard.
There is even debate on whether truly ethical down can even exist on a large scale. If you’re in this camp, you might want to simply consider synthetic insulation.
SYNTHETIC INSULATION
Comparison of our two top synthetic insulated vests.
Synthetic insulation uses polyester or nylon spun into loosely-bunched fibers to create an insulation material that mimics the qualities of down. Synthetic insulation is often cheaper than down, and can be made with recycled plastic. Some synthetic insulation itself can even be recycled.
Synthetic insulation doesn’t compress as much as down when it gets wet, so it retains a lot of its insulating properties. If you’re going to be using your insulated vest in rainy conditions or humid environments, synthetic insulation is a better choice.
The Montbell Thermawrap is our winner for best synthetic puffy vest.
A synthetic puffy vest is generally more packable than a fleece vest, which is also warm when wet and quick-drying. However, synthetic puffy vests are more packable and have a better warmth to weight ratio.
Synthetic insulation is sometimes made of recycled materials. While we didn't have a chance to test it, the LL Bean Primaloft Packaway vest or The North Face Thermoball Eco Vest, both use synthetic insulation. The LL Bean Packway jacket won best affordable women's and men's jacket in our Synthetic Insulated jacket guide and uses Primaloft and NASA. The recycled Thermoball insulation is found in The North Face Thermoball ski jacket, which we review in our ski jackets guide.
An insulated vest with synthetic insulation is also vegan. If you’d like to avoid the thorny issues surrounding down insulation, we think synthetic is the way to go.
HYBRID
A hybrid insulated vest uses a combination of down and synthetic insulation. This lets you have the best of both worlds: you get the warmth and compressibility of down with the breathability and warmth-when-wet properties of synthetic insulation, all in one layer.
Hybrid insulated vests, such as the Arc'teryx Cerium Vest or the Mammut Albula IN Hybrid Vest often have down insulation in the areas that won’t see as much sweat, such as the chest and shoulders, and synthetic insulation in areas that will see more moisture, such as under the arms. This gives you the lightweight packability of down and the moisture-resistant warmth of synthetic insulation in only the spots you truly need it. We didn't have a chance to test the Arc'teryx Cerium Vest or any hybrid vest, but the Arc'teryx Cerium Hoody performed well and is an award winner in our Best Down Jackets and Best Synthetic Insulated jackets guides.
WARMTH
Outdoor Vitals NovaPro vs. Patagonia Down Sweater vs. Outdoor Research Cold Front.
Generally speaking, the puffier a vest looks, the warmer it will be. Puffier vests are usually bigger because they’re stuffed with more insulation, and vests with more insulation are going to be warmer. However, more insulation is also heavier, so you’ll have to balance warmth with weight.
Generally, down jackets will have a better warmth to weight ratio than synthetic jackets. However, while we didn't have a chance to test it, the LL Bean Primaloft Packaway vest uses a synthetic insulation called Primaloft Gold Insulation injected with NASA-designed Aerogel. For the amount of warmth it provides for the price, the LL Bean Packway jacket won best affordable women's and men's jacket in our Synthetic Insulated jacket guide.
Comparison of the collars on some of the vests we tested. Note how some have a fleece lining on the inside to prevent the zipper from rubbing against your chin.
WEATHER RESISTANCE
Synthetic insulation has better weather resistance than down insulation. Most down is treated with a weather-resistant coating, but it will still eventually get wet and lose its insulating properties if exposed to a lot of weather.
FILL POWER
Outdoor Research Cold Front and Outdoor Vitals NovaPro, two of the highest fill power jackets.
Fill power is a measurement used to assess the loft or insulating capability of down-insulated vests or other down items.
Fill power is usually expressed in cubic inches per ounce (in3/oz). If a down vest has a fill power of 800, that means one ounce of down occupies 800 cubic inches. The same amount of down from a 1000-fill insulated vest expands to 1000 cubic inches. In short, the higher the fill power, the fluffier.
Higher fill power insulated vests are more expensive since the down used is higher quality. Higher fill power is also more compressible, so you can pack them smaller.
The vests we tested maxed out at 800 fill down. However some brands like Feathered Friends use 900 fill down. We hope to test the Feathered Friends Eos Vest in future updates to this story.
On warmer days, a breathable vest will help keep you cooler when moving.
BREATHABILITY
Breathability matters most in high-intensity activities such as cold-weather cycling, hiking, running, or alpine climbing. Breathable insulation allows sweat to evaporate, which helps to keep you cool and comfortable.
Breathability is one of the top reasons to choose a synthetic jacket over a down-filled jacket. Synthetic insulation is generally more breathable than down. If breathability is a top concern, then we recommend you get a synthetic puffer vest. The water vapor your body produces when you sweat doesn’t move through down insulation as well as it does through synthetic.
When your sweat doesn’t move through insulation, you’ll be hot, wet, and uncomfortable. It will eventually make you colder when you stop moving, too. Highly breathable synthetic insulated vests and jackets are often called “active insulation” because they breathe the best.
INTENDED USE
You should choose a puffy vest that works for how you intend to use it. A vest that keeps you warm when your body isn’t generating body heat will be too warm while exercising. A vest that looks good in casual settings might not keep you warm enough or breathe enough for use in high-output activities, either.
One use of a vest is lightweight additional warmth for days when you don’t think you’ll need a full jacket. On those days, the weight and packability of your vest will matter more.
You may want an insulated vest that will keep you warm enough when you aren’t being active. A puffer vest for this use will have a higher fill weight, or thicker insulation. Or, you might want a vest that will keep you a little warmer while you move. An insulated vest for active situations will be thinner, with a lower fill weight. Also, a vest for active use is probably filled with synthetic insulation because it breathes better.
SHELL FABRIC
Comparison of shell fabrics on some vests.
Most puffer vests use a thin polyester or nylon shell fabric on the outside and inside of the vest. This shell material is just thick enough to not tear easily while still being light enough to make an insulated vest packable.
SUSTAINABILITY
Many puffer vests use recycled plastic to make the shell fabric, synthetic insulation, or both. There are companies that use recycled down insulation in their vests as well.
Most companies use some amount of recycled content in their insulated vests at this point, and they all use this in their marketing materials. But, some companies go beyond adding recycled content to their products, and those are the ones that are truly leading the charge in sustainability.
DURABILITY
The shell fabric of an insulated vest might have a ripstop weave pattern, which prevents small snags from turning into large tears in the fabric. A ripstop shell fabric is important for durability because the thin material would otherwise develop large holes anytime you snagged it on a tree branch or other sharp edge.
Some puffer vests are made with a thicker shell material, too. This thicker material will be more resistant to tears, whether or not it has a ripstop weave. This thicker shell material will be heavier, though.
Comparison of some of the vests side-by-side. Note how some have a more boxy fit while others are more tapered.
SIZE AND FIT
If you plan to layer an insulated vest on top of warm winter layers, then take that extra bulk into account when sizing an insulated vest. If you’re only planning on wearing your insulated vest over trim-fitting shirts or base layers, then you could probably get a smaller-size vest than if you wanted to wear it over a thick sweatshirt.
WEIGHT
Comparison of down vests side-by-side as stored in their stuff sacks. We weighed each one on our home scale.
Insulated vests are often lighter than full-sleeved puffy jackets, but there are definitely lighter-weight and heavier vests you can choose from. If you plan on carrying your insulated vest backpacking in the summer, you should consider getting a lightweight vest that will be easier to carry on your back. If you’re going to be wearing your puffer vest during cold weather, weight is also important, but an ounce or two more might mean that the insulated vest you’re skiing or snowboarding in will breathe better.
COMPRESSIBILITY
Left to right: Mountain Hardwear Ghost Whisperer, Montbell Thermawrap, and Patagonia Nanopuff, three of the most packable vests.
Much like weight, compressibility is important if you plan on carrying your insulated vest in a backpack. The more you can compress your puffer vest, the more space you’ll have in your pack for everything else you need to carry.
Generally speaking, down insulation is more compressible than synthetic insulation. So, a down-insulated vest is going to be more compressible than a synthetic insulated vest.
If you store your puffer vest compressed for a long time, that insulation will lose its long-term ability to loft, making it less warm. For this reason it’s best to store your down or synthetic vest on a hanger in your closet rather than stuffed into a stuff sack or pocket.
POCKETS
We compared pocket placement and size on each vest, especially whether it could fit a phone.
Most insulated vests have hand warmer pockets. Some also have a chest pocket, which is a great place to keep a smartphone in cold weather both for your easy access to it and to protect its battery life. Some vests don’t have any pockets at all. These are probably the lightest vests you’ll find, but lack the functionality that pockets provide.
HOOD
Hooded vests are less common because many folks choose to layer their vest with a hooded baselayer, as we did here.
There are many puffer vests that come with a hood, but hooded vests are less common in general. Whether you get a hooded puffer vest or not is ultimately a personal choice.
A hood is a useful feature for keeping your head and neck warm. A hood also adds extra bulk to an insulated vest, and might be more than you need if you also plan to use a beanie, neck gaiter, or both. A hood will also add weight to your insulated vest. It will probably also mean that vest costs more than its non-hooded counterpart.
I personally love hoods on most of my insulated layers. But in many scenarios where I’m wearing a puffer vest, I probably have a hooded layer underneath the vest. So a hooded vest will just be extra material to get in the way when layering. Plus, a hooded vest is harder to layer on top of, and vest + windbreaker is a great combination. The hood just gets in the way when putting a jacket over a vest.
PRICE AND VALUE
Most of the vests we tested here provide a good value, but they do vary in price. Depending on your needs, you might want to choose a more expensive insulated vest that will keep you warmer, breathe better, be more lightweight, or be more durable than a less expensive vest. This means that the more expensive vest might be a better value, especially if you plan to use it for a long time.
HOW WE TESTED
We tested insulated vests in the mountains of Colorado and Wyoming during late summer and fall. We also wore them around town on chilly mornings and late nights. In any instance where we would have otherwise grabbed our trusty puffy jacket, we wore one of these vests instead. And, we’re often in cold places, and love being warm, so we wore these vests a lot.
We wore them in the alpine on mountain runs and on hiking and backpacking trips. We tested them for durability by carrying them in our packs, and wearing them with a backpack. We tested puffer vests for warmth on cold nights camping in the mountains.
We weighed each vest to get a comparison of how they stacked up side-by-side.
We wore them around town on chilly mornings to get a sense of how comfortable each vest was. We carried them in our frame bag while riding our bike on Colorado’s Front Range and around town when commuting as an extra layer for late nights and early morning bike rides.
Here, we’re layering this lightweight vest with a thicker midweight sweater. You can also layer vests with lightweight base layers.
FAQ
WHAT DO YOU WEAR UNDER A DOWN VEST?
You can wear any shirt you want under your down vest. Adding a down vest on top of any shirt will make you warmer. The warmer the shirt you have under a down vest, the warmer you will be with a down vest on top. Remember to size your down vest based on what you're planning to wear underneath. For example, many outdoors people wear down vests over slim-fitting base layers, but others choose to wear down vests over light jackets or a fleece jacket.
SHOULD A DOWN VEST BE TIGHT?
A down vest should be tight enough so that it isn’t too baggy, but not so tight that it’s uncomfortable. You should get a down vest that will comfortably fit over any clothing you want to wear under it. Pay extra attention to the tightness of a vest in the arm holes. If the arm holes are too tight you won’t be able to fit a thicker sweater underneath the vest.
WHAT’S THE DIFFERENCE BETWEEN DOWN AND SYNTHETIC INSULATION?
Down insulation is a natural insulation that comes from ducks, geese, or other waterfowl. Synthetic insulation is made of non-natural polyester or nylon materials and is made to mimic down insulation.
ARE INSULATED VESTS SUITABLE FOR EXTREME COLD?
Insulated vests are suitable for extreme cold if used with other insulated jackets. Adding an insulated vest on top of another insulated jacket can bea suitable combination of layers for cold weather. But, an insulated vest without another jacket isn’t suitable on its own for extreme cold.
Comparison of how different down vests pack down.
CAN INSULATED VESTS BE PACKED EASILY?
Insulated vests pack down very easily. Insulated vests compress down to a small size, so they’re great to carry with you in a small backpack. Many outdoors people choose to carry a down vest because it packs down more easily than a down or synthetic jacket.
WHAT TEMPERATURE SHOULD YOU WEAR A PUFFER VEST?
You should wear a puffer vest in moderately cold temperatures, down to about 40 degrees Fahrenheit. In temperatures below 40 degrees, you can combine a puffer vest with another insulated jacket, fleece, or thicker base layer to stay warm.
WHY DO BANKERS WEAR VESTS?
Bankers wear vests to stay warm and comfortable in banks, which are often cold. An insulated vest fits in with the business casual style required of bankers, too. We tried wearing a puffy jacket to a job interview at a large bank and told the hiring manager that it would keep us warm in the overly air conditioned and potentially soulless environment. We didn’t get the job.
Check out the Instagram account midtown uniform for a slew of photos of white men in the official banker’s uniform–button down, slacks, and a vest. We should have checked out this account before showing up to that job interview in dirty trail runners, running shorts, hiking shirt, and puffy jacket.
ABOUT THE AUTHOR / WHY YOU SHOULD TRUST US
Sam Schild is a thru-hiker, trail runner, cyclist, and mountain athlete based in Colorado. After moving to Colorado a decade ago, he discovered the benefits of the puffy jacket, then later the slimmed-down sleeveless version, the insulated vest.
He has thru-hiked the Pacific Crest Trail, Continental Divide Trail, Grand Enchantment Trail, and the Colorado Trail twice.
He has bikepacked the Colorado Trail, Kokopelli Trail, Sky Islands Odyssey Route twice, and completed a 7,000-mile cross-country bikepacking trip.
On all these trips, he’s carried a puffy jacket, but spent too much time considering whether the perfect insulated vest might be a better choice. Now he’s convinced that sometimes a vest is all you need.
You can read more about Sam on his author page or on his website.
