What fabric should you choose?

Here’s the simplest possible flowchart I could make for my recommendations. You can use it based on your priorities. If you want more nuance and specification, read further below.

Standard selection

I’ve chosen the most suited fabrics for the standard packs. I spend a lot of time testing and evaluating the performance of these fabrics. This means most packs consist of a multitude of different fabrics, suited for different purposes and not just a single fabric for ease of manufacturing. You can read more about the materials if you are putting together a custom pack or simply interested.

Lightweight 2-layer laminates

Ultra

A higly technical fabric with amazing properties and a few drawbacks. The face has a high content of UHMWPE which has great abrasion resistance. Perfect for simple, low weight, durable and waterproof packs. 

200 denier face of 67% ultra high molecular weight polyethylene/UPE blended with 33% polyester and waterproof 0,5mm polyester RUV-film.

Polyester components are 100% recycled.

Weight: 119 gsm
Abrasion: 4400 cycles
Tear strength: 459 N warp/592 N weft
Waterproof

EPLX

Light waterproof fabric
More stable all-polyester construction.

200 denier polyester face, 45° polyester Cross-ply and waterproof 0,5mm polyester RUV-film.

Polyester components are 100% recycled.

Weight: 146 gsm
Abrasion: 500 cycles
Tear strength: 459 N warp/592 N weft
Waterproof

Long lasting 3-layer laminates

UltraTX

The best of both worlds – the abrasion resistance of Ultra with the increased stability and prolonged waterproof lifespan of a 3-layer laminate. The ultimate choice for long lasting frame packs!

Ultra200TX

200 denier Ultra face, 45° polyester Cross-ply and 70 denier polyester ripstop backing.

Polyester components are 100% recycled.

Weight: 200 gsm
Abrasion: 4400 cycles
Tear strength: 459 N warp/592 N weft
Waterproof

Ultra400TX

400 denier Ultra face, 45° Ultra Cross-ply and 50 denier double ripstop polyester backing.

Polyester components are 100% recycled.

Weight: 244 gsm
Abrasion: 8800 cycles
Tear strength: 459 N warp/592 N weft
Waterproof

EPX

Solid 3-layer fabric with long waterproof lifespan made from 100% recycled components.

C0 DWR, 200 denier polyester face with 45° Cross-ply, and 70 denier polyester ripstop backing. 

Weight: 200 gsm
Abrasion: 500 cycles
Tear strength: 119/110 N
Waterproof

Hybrid

The special coating adds incredible abrasion resistance. It has longer lasting waterproofing compared to the conceptually similar Liteskin fabric. A great option when a rugged pack outweighs a few grams saved.

Liquid crystal polymer coating, 400 denier face of nylon/polyester mix with 45° Cross-ply and 70 denier polyester ripstop backing.

Polyester components are 100% recycled.

Weight: 310 gsm
Abrasion: 15000 cycles
Tear strength: 166 N warp/151 N weft
Waterproof

Non-laminated fabrics

Ultragrid

If you don’t need any meaningful waterproofing but rather a simple, light and tough fabric, this is it.

200 denier recycled nylon face with double Ultra ripstop

Weight: 132 gsm
Abrasion: 1100 cycles
Tear strength: NA
Waterproofing: 1500mm

Let's compare

Properties like waterproofness, abrasion resistance, tensile strength, and tear resistance can be measured in a standardized way. Therefore, they tend to be the most common way fabrics are compared. However, they only hint at the longevity and performance of a fabric, as real-world usage differs wildly. Comparison chart of fabrics I offer with some common alternatives ranked by weight:

Fabric Weight (g/m2) Abrasion (ASTM 3884 cycles) Tear strength warp/weft avg (N) Waterproof Recycled components
DCFH50 102 500 191 Yes 0%
Ultra200 119 4400 516 Yes 40%
Ultragrid 132 1100 na No 90%
DCFH150 170 500 245 Yes 0%
RBC400 178 3000* na No 90%
Ultrastretch 186 3000 na No 0%
EPX200 200 500 115 Yes 100%
VX21 210 500 93 Yes 0%
Ultra200TX 210 4400 516 Yes 60%
Ultra400TX 244 8800 689 Yes 55%
EPX400 304 3000 159 Yes 100%
EPX400HH 310 15000 159 Yes 48%

*based on fabrics with the same face

What can the numbers be used for?

In my experience, face fabric correlates better with real-world performance than most other metrics. Fabrics that score low for their face denier generally perform slightly better in real world conditions than standardized tests would suggest. The opposite is also true.
Example: The ~200 denier polyester face of EPX/EPLX/VX holds up better than the 50 denier polyester face of DCFH50, even though they score the same in abrasion testing. Ultra200 doesn’t perform an order of magnitude better than DCFH50, but it is still significantly stronger. 

Limitations

The amazing properties of UHMWPE used in Ultra are not without caveats, as it is very slippery and has a low-energy surface, meaning it makes for an unstable weave that is hard to bond. This is why Ultra has 1/3 polyester in the face. It stabilizes the weave and allows stronger bonding of the film, which further stabilizes the fabric as a whole. The film is then not just for waterproofing, but also an integral part of the fabric. This means the fabric tests quite a bit higher than its real world durability in a lot of conditions as the film also deteriorates and the integrity of the fabric gets compromised.

Being mindful of sharp objects inside your pack and seam taping helps prevent premature damage to the film. You can’t simply adapt existing design and construction method and expect good resuslts. This is especially true for frame packs as the structure and higher loads create larger stresses and internal abrasion. This is why I only offer Ultra for specific designs, which can be 100% seam taped and also reinforce key areas to prevent internal abrasion. If you want something that will last a long time, even with sharper metal bits involved, a 3-layer material will be better suited, albeit with some added weight and lower initial waterproofing.

A note on waterproofing

While all the main fabrics are waterproof to over 200psi (140000mm HH!), packs made from them are not equal in waterproofing, especially over time.

2-layer fabrics like Ultra and DCF have the waterproof film exposed, cutting weight and allowing effective seam taping. The film is more susceptible to abrasion and will deteriorate over time, especially if you carry sharper objects inside the pack.

3-layer fabrics have a backing that significantly increases internal abrasion resistance and seam fastness. It does adds some weight and makes sealing significantly harder.

A seam-taped 2-layer pack will start out lighter and more waterproof, but can be overtaken by a 3-layer pack in terms of waterproofing. This is magnified for larger and complex packs.

Pocket materials

RBC400

Simple 400D polyester with a plain and tight weave. Great durability and supple hand. 100% recycled. Perfect for pockets that don’t need waterproofing.

Gridstop

210D nylon with UHMWPE ripstop. The reinforcement yarn increases tear resistance while maintaining a smooth surface for better abrasion resistance compared other types of ripstop materials. It also gives a high tensile strength and the supple hand, which makes it perfect for the load of straps.

Ultra stretch

Lightweight, durable, and tear-resistant 4-way stretch mesh woven with the highest quality fibers for performance and longevity. Great for bottom pockets and other lower volume pockets.

Open mesh

Fast drying and tough, due to being 100% polyester and non-elastic. Leaves the contents more visible and easier to dry. Can snag on brush.

Custom selection

The full breadth of fabrics and colors is available for you to pick and match when you order a custom pack. They are subject to availability.

EPLX

Light waterproof fabric

200 denier polyester face, 45° polyester Cross-ply and waterproof 0,5mm polyester RUV-film.

Polyester components are 100% recycled.

Weight: 146 gsm
Abrasion: 500 cycles
Tear strength: 459 N warp/592 N weft
Waterproof