Backcountry Backbone:

Engineering Ultralight Carbon Fiber Stays for Elite Packs

Industry: Outdoor Recreation
Location: NATIONALLY

We partnered with U.S. based outdoor brands to engineer and manufacture next generation carbon fiber backpack stays built for the extreme demands of backcountry use. Designed for an optimal balance of strength, controlled flex, and minimal weight, these aerospace-grade components deliver reliable performance in rugged, load-intensive environments, all manufactured in the USA.

About

We work closely with each manufacturer to develop and produce their distinct backpack designs, tailored to their specifications and performance requirements. These ultralight, high-performance systems are built for backcountry hunters and mountain athletes, engineered to carry heavy loads across extreme terrain without excess weight. Modular, minimalist pack architectures place high demands on internal frame components, making precision-engineered carbon fiber stays a critical structural element. Designed to balance comfort, durability, and load-hauling performance, these systems rely on advanced materials and tight tolerances to perform reliably in remote, demanding environments.

< 4 oz
FINAL WEIGHT
PER STAY

10-20%
MASS REDUCTION 

Challenge

  • Achieving consistent stiffness and flex response across production runs
  • Holding tight layup, trim, and dimensional tolerances at scale
  • Coordinating manufacturing schedules with fixed, season-driven launch windows
  • Increasing structural efficiency to support heavy loads while lowering overall weight
  • Tuning flex behavior to manage dynamic loads without sacrificing comfort or control
  • Minimizing material waste while maintaining predictable, repeatable production costs

Solution

Southwest Composite Works developed a proprietary manufacturing process to address the demands of high-performance carbon fiber components. The process is engineered to optimize strength along the primary load axis while minimizing unnecessary mass. Key features include:

  • Enhanced Strength and Consistency: Delivers reliable load support while preserving precise flex characteristics.
  • Dimensional Accuracy: Refined layup and trim methods ensure repeatable, production-scale consistency.
  • Lightweight Efficiency: Reduces overall mass without compromising durability or performance.
  • Optimized Production: Iterative prototype testing and agile scheduling maintain delivery timelines and reduce material waste.

200+ lb
FLEX LOAD TESTING
WITH NO DELAMINATION

±0.010"

PRODUCTION CONSISTENCY ACROSS MULTIPLE RUNS

Parts Manufactured

Each stay is carbon fiber, compressed under high pressure using custom tooling developed in-house by Southwest Composite Works.

Critical manufacturing advantages include:

  • 3-axis CNC-machined tooling for precision molding and repeatability.
  • Controlled manufacturing for predictable stiffness and durability.
  • Post-process finishing to maintain tight tolerances for frame integration.

All stages, from layup through final inspection, are completed in the USA, ensuring full supply chain transparency and quality assurance.

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What Made This Project Unique

Backpack stays must deliver a rare combination of rigidity and flex, all while being ultralight and incredibly durable. Each stay had to fit seamlessly into proprietary pack frames, requiring tight tolerances and consistent material performance, especially across varied and rugged terrain.

    Final Outcome
    • Production ready carbon fiber stays that met or exceeded client performance benchmarks
    • Successfully integrated into flagship backpack models
    • Withstood long-distance, high-load use cases without structural failure

    Molding the future with carbon fiber composites.

    START YOUR PROJECT TODAY
    or Give Us a Call: 505-237-9883