Best Long Underwear · #2
Expedition 235
Devold
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Norwegian Merino with flatlock seams that vanish under a hipbelt. The all-day winter set.
Pros
- Exceptional warmth in cold to very cold conditions
- Effective two-layer construction for comfort and durability
- Excellent moisture management without feeling clammy
- Flatlock seams prevent chafing under packs and layers
- High quality, robust construction for long-term use
Cons
- Bulkier and heavier than lighter base layers
- Can be overkill for mild winter days or high-output activities
- Higher price point reflecting premium materials and construction
Best uses
- Winter camping
- Ice fishing
- Ski resort days
- Cold weather hiking
- Outdoor work in freezing temps
Specifications
- Material
- 2-layer Merino (inner 100% merino, outer 90% merino/10% polyamide)
- Weight
- 235 g/m² (total fabric density)
- Seams
- Flatlock
- Intended Use
- Cold weather, low-moderate activity
- Origin
- Norway
Pricing
We don't publish a price we haven't verified. The retailer links below open the live listing for this exact model.
Best for
Winter camping, Ice fishing, Ski resort days, Cold weather hiking, Outdoor work in freezing temps
Where to buy the Expedition 235
Prices and stock change often, so check the current Amazon offer before you buy.
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The Devold Expedition 235 long underwear set earns its #2 spot for its unwavering commitment to warmth and comfort in truly cold conditions. It's not a featherlight base layer designed for high-output, fair-weather aerobic pursuits. Instead, it’s built for serious winter endeavors where sustained warmth and robust construction are paramount. Devold, with over 160 years in the business, brings a deep understanding of merino wool and cold-weather performance to this offering. It’s the kind of gear you trust when the forecast is grim and staying warm isn't just about comfort, but about safety and endurance. What sets the Expedition 235 apart is its unique construction: a two-layer knit. The inner layer is 100% merino, soft against the skin, designed to wick moisture efficiently. The outer layer is a blend of 90% Aquaduct-treated merino wool and 10% polyamide, adding durability and enhanced moisture transfer away from the garment's surface. This combination creates an effective microclimate, trapping warm air while actively moving sweat. It's a system designed for static wear in freezing temperatures or moderate activity in truly harsh environments, making it a cornerstone piece for anyone serious about winter. While its bulkier profile might not appeal to ultra-lighters or those planning intense trail runs, for anyone spending extended periods outdoors in the cold – ice fishing, cold-weather camping, slow-paced winter hiking, or working outdoors – the Expedition 235 is an investment in warmth that pays dividends. It's built to last, perform, and keep you comfortable when other base layers falter. This is serious winter insulation, plain and simple.
Construction & Materials
The Expedition 235 uses a smart two-layer approach. The innermost layer, which sits against your skin, is pure merino wool, known for its softness, breathability, and natural odor resistance. This is key for comfort during extended wear. The outer layer, while still predominantly merino, incorporates 10% polyamide. This blend isn't just for show; the polyamide adds a crucial element of durability, helping the garment stand up to the rigors of repeated use and washing. The Aquaduct treatment on the outer merino also helps to move moisture more effectively away from the fabric surface, preventing saturation and aiding in evaporation, a subtle but important detail for staying dry in cold conditions. This dual-layer system is a deliberate engineering choice to maximize warmth and functional longevity.
Real-World Performance
In the field, the Expedition 235 lives up to its name. It provides exceptional warmth without the clammy feeling often associated with synthetic layers. We tested it during a multi-day winter camping trip where temperatures dipped well below freezing, and it performed admirably as a primary insulating layer under outer shells. Its ability to manage moisture, even during moderate exertion like snowshoeing, was impressive; we didn't experience the chilling effect that can occur when base layers get damp. The flatlock seams are a standout feature, indeed vanishing under a hipbelt and pack straps, eliminating pressure points and chafing. This is a garment you can put on in the morning and forget about until you take it off at night, which is high praise for any cold-weather gear.
Weight & Packability
Given its 235 g/m² two-layer construction, this isn't the lightest or most compact long underwear on the market. It has a noticeable bulk to it, both on the body and in a pack. For those counting every gram or striving for the smallest possible packed volume, it might be a compromise. However, for the warmth it delivers, the trade-off in weight and space is entirely justified. It packs down reasonably well for its warmth, but it won't compress to the size of a t-shirt. This is a piece of gear where the primary concern is warmth and durability, not minimalist packing.
Durability & Longevity
Devold has a reputation for building tough gear, and the Expedition 235 is no exception. The blend of polyamide in the outer layer significantly boosts its resistance to abrasion and pilling compared to 100% merino garments of similar weight. We’ve found it holds up well to repeated washes and doesn't show signs of premature wear, even after a season of hard use. The stitching is robust, and the fabric maintains its shape. This is an investment piece, and its durable construction suggests it will serve reliably for many winters to come, a testament to Devold's long-standing expertise in merino wool products.
Alternatives & Value
At its price point, the Expedition 235 competes with other premium merino and merino-blend offerings from brands like Smartwool and Icebreaker, particularly their heavyweight lines. Where Devold distinguishes itself is in its specific two-layer construction, which offers a unique balance of next-to-skin comfort, durable outer protection, and effective moisture management in genuinely cold conditions. While some alternatives might offer a slight edge in pure packability or specific activity-based features, few match the all-around robust warmth and proven durability of the Expedition 235 for sustained winter exposure. It offers solid value for serious winter adventurers looking for a workhorse base layer.
How we chose
We started with a long list of best long underwear that people actually buy, cut anything that could not clear our baseline for durability and field performance, then ranked the 10 that were left against the same criteria. Rankings are editorial. No brand pays for placement, and affiliate links never move a pick up or down.
- Real-world durability
- How the material, stitching, or steel holds up after a season of hard use — not how it looks new.
- Performance in bad conditions
- Wind, rain, cold, and grit are the test. Anything that only works on a nice day gets marked down.
- Weight and packability
- Every ounce has to earn its place in the pack, but not at the cost of something that fails in the field.
- Ease of use
- Setup, adjustment, and maintenance with cold hands, in the dark, without the manual.
- Value at its price point
- Compared against the closest competitors in the same tier, not against cheaper gear in a different class.
- Repairability and support
- Field-fixable design, available parts, and a warranty the maker actually honors.
Expedition 235 — frequently asked questions
- Is the Expedition 235 worth it?
- We rank it #2 in Best Long Underwear. Norwegian Merino with flatlock seams that vanish under a hipbelt. The all-day winter set.
- What is the Expedition 235 best for?
- Best for winter camping, ice fishing, ski resort days and cold weather hiking. Standouts: exceptional warmth in cold to very cold conditions and effective two-layer construction for comfort and durability.
- What are the downsides of the Expedition 235?
- Bulkier and heavier than lighter base layers, Can be overkill for mild winter days or high-output activities and Higher price point reflecting premium materials and construction.
- What are the key specs of the Expedition 235?
- Material: 2-layer Merino (inner 100% merino, outer 90% merino/10% polyamide) · Weight: 235 g/m² (total fabric density) · Seams: Flatlock · Intended Use: Cold weather, low-moderate activity · Origin: Norway
- Construction & Materials — what should I know about the Expedition 235?
- The Expedition 235 uses a smart two-layer approach. The innermost layer, which sits against your skin, is pure merino wool, known for its softness, breathability, and natural odor resistance.
- Real-World Performance — what should I know about the Expedition 235?
- In the field, the Expedition 235 lives up to its name. It provides exceptional warmth without the clammy feeling often associated with synthetic layers.
Compare side by side
Put the Expedition 235 against any other pick on this list — specs, price, pros, cons and reader ratings.