Consumer ProductsSportsWearables

Osprey presents UNLTD, a backpack with 3D printed reinforcements

The first to use Carbon DLS technology

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After the recent project from VAUDE, Osprey, a leader in top-quality, high-performance packs presented Osprey UNLTD, an industry-changing pack series that harnesses rapidly emerging technology and materials such as Carbon DLS, previously untapped by the backpack industry. Production was once again provided by OECHSLER, an unrivaled specialist in this field.

“Osprey UNLTD is the manifestation of Osprey’s approach to innovation,” said Rob BonDurant, VP Marketing, Osprey Packs. “In developing Osprey UNLTD, we removed the shackles of commercialization and production schedules to move beyond traditional manufacturing technologies ushering in a new era of backpack design and the ultimate backpacking experience.”

Osprey presents UNLTD backpack with 3D printed reinforcements - the first to use Carbon DLS technology UNLTD is the result of a two-year design journey led by Osprey Co-Founder & Director of Innovation, Mike Pfotenhauer and Osprey’s Innovation Team. Key to UNLTD’s design is Osprey’s usage of Carbon DLSTM 3D technology to engineer the pack’s lumbar. Osprey is the first pack manufacturer to harness Carbon DLSTM technology. The result is UNLTD’s 3D-Printed FitscapeTM Lumbar which delivers superior ventilation, fine-tuned cushion support, and an anti-slip surface grip to keep loads firmly in place while reducing manufacturing waste.

“Traditional manufacturing methods teach us that in order to push the boundaries of innovation, product development timelines need to be extended. The development of Osprey UNLTD proved the exact opposite,” said Phil DeSimone, Carbon co-founder, chief product and business development officer. “The entire process using Carbon DLS took about one year with only six months for us to iterate on the design, enabling Osprey to take this innovative product to market faster.”

In addition to the revolutionary 3D Printed Fitscape Lumbar, UNLTD features an innovative Autolift System that comfortably and efficiently distributes the load while seamlessly including Fit-On-The-Fly adjustment into the overall structure of the shoulder straps. UNLTD features state-of-the-art fabrics, including a double rip 210D lightweight main fabric with UHMWPE (ultra-high molecular weight polyethylene) content that is both lightweight and durable. Other notable details include a deluxe rain cover made from premium high tenacity nylon ripstop as well as a custom Airporter Cover with lockable zippers designed to shield and secure the pack during transit.

The ANTI-GRAVITY 64 (priced at £650), Osprey’s Anti-Gravity Suspension – a 3D-suspended mesh – contours the body while a seamless suspended mesh extends from the shoulder blades to the lumbar area to the hipbelt. The packs will be sold with a certificate of authenticity and a unique serial number, a unique clamshell compression system supported by an internal frame, that opens and closes like a clamshell, providing structure and easy access to the upper pack, as well as an enhanced compression system and a removable top that transforms into a fully functional convertible top-lid waist pack with hydration hose port and lumbar pad.


Research 2022
Polymer AM Market Opportunities and Trends

741 unique polymer AM companies individually surveyed and studied. Core polymer AM market generated $4.6 billion...

Edward Wakefield

Edward is a freelance writer and additive manufacturing enthusiast looking to make AM more accessible and understandable.

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