Modular Pack System
Summit Gear Co.
Client
Summit Gear Co.
Year
2023
Services
Product Design, Prototype Development, Manufacturing
Materials
500D Cordura, Glass-Filled Nylon, YKK Aquaguard
Overview
The Pack System replaces the 'one bag for every occasion' problem with a single platform that adapts. A rigid frame accepts interchangeable modules — daypack, camera insert, hydration bladder, tool roll — via a proprietary click-mount system. We designed the mount system, all modules, and managed textile manufacturing.
Challenge
Modular systems typically add bulk and complexity. The click-mount had to be secure enough for mountain scrambling, light enough for trail running, and simple enough to swap one-handed with gloves. Textile manufacturing introduces tolerance challenges that hard-goods designers often underestimate.
Approach
The click-mount uses a glass-filled nylon rail system inspired by camera quick-release plates. Three contact points provide 50kg of shear resistance while releasing with a single thumb motion. We developed custom sewing jigs that constrain rail placement to ±0.5mm — tight enough for reliable module engagement across all production units.
Outcome
The Pack System launched to a sold-out first run. Outdoor Magazine named it 'Gear of the Year' and the modular concept has spawned a community of third-party module makers. Return rate is under 2% — exceptional for a product with multiple interacting components.
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