Weightless Backpack Design Case Study

Key Product Design Challenges

Balance and positioning on different body sizes

Positioning of pivot points and frame angles to ensure weight remained balanced and the whole bag sits correctly on a variety of body sizes was a key challenge. One minor change could affect other aspects and make the product uncomfortable on certain users. An iterative prototyping process was required to test out ideas with runners and cyclists.

Unique Strap arrangement and chest buckle

Changing the way a back pack’s straps traditionally run over the shoulders and down the body presented a complex challenge. A buckle that is easy to attach, allows for chest expansion when breathing, and sits comfortably on the chest plate for men and women was developed. Many different connection mechanisms and shapes were explored. As with the above, the buckle plays a key role in maintaining the correct angles and positioning on the body. Furthermore the buckle needed to be easy to take on and off. Whilst looking appealing. This resulted in a complex plastic moulded design and padding combination.

Collapsible suspension system

Designing functionality that allowed the sprung and damped suspension and hip belt to collapse down so that the bag can sit upright on the floor or desk. Of course all the weight of the bag runs through this system and this therefore presented a challenge for us not to compromise the structural integrity in any way. Further complications came from the frame and suspension components being curved to fit the body. This meant there was no direct straight line route to slide parts. In the end a rotationally moulded curved slider tube and lock system was designed and incorporated in to the suspension geometry.