I’ve been working on a custom 30L backpack for a while now. The frame is made from 7075 aluminum, and I’ve used a mix of Dyneema and Cordura for the panels. Any thoughts on how to improve the comfort without adding too much weight?
Custom Backpack
The padding system makes a huge difference. Try using a 3mm closed‑cell foam sandwich with a breathable mesh cover. It adds just ~150g but feels noticeably softer on long hikes.
If you’re up for it, a quick‑release buckles system can make it easier to access the interior. I used 2.5mm aluminum clips and they hold up well to 150 kg load.