Osfrey Unltd

Osprey unveils Unltd pack that makes best use of 3D Printing

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Osprey has introduced Osprey Unltd, a new-generation backpack series featuring a 3D-printed technology developed in collaboration with Carbon.

The Californian backpack manufacturer said Unltd is the result of two years of experimentation led by Osprey’s innovation team and its director Mike Pfotenhauer, in which they employed Carbon’s technology to produce the pack’s 3D-printed lumbar.

Osprey Unltd 3D printed back element
The 3D printed element provides graded cushioning, ventilation, and a grip that keeps the pack in place

Unltd’s 3D-printed lumbar is meant to deliver improved ventilation, fine-tuned cushion support, and an anti-slip surface grip to keep loads in place.

“Osprey Unltd is the manifestation of Osprey’s approach to innovation,” said VP of marketing at Osprey Rob BonDurant.

“In developing Osprey Unltd, we removed the shackles of commercialisation and production schedules to move beyond traditional manufacturing technologies ushering in a new era of backpack design and the ultimate backpacking experience.”

Employing 3D printing in manufacturing, Osprey said, also allowed to reduce material waste and speed up time to market.

Osprey Unltd


“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, chief product and business development officer at Carbon.

“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 3D-printed lumbar, Osprey Unltd also features an autolift system that should contribute to distributing the load and a fit-on-the-fly hip belt with a silicone grip that should prevent load slippage.

The backpack, made of innovative materials including a double rip 210D fabric with ultra-high molecular weight polyethene, also features a raincoat made from nylon ripstop and a cover with lockable zippers designed to shield and secure the pack during travel.

Produced in two styles, Osprey Unltd AirScape 68 and Osprey Unltd Anti-Gravity 64, both available in men’s and women’s versions, the pack has a RPR of £650.

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