Osprey, a high-performance backpack manufacturer, has used Carbon's DLS 3D printing technology to create a 3D printed lumbar for its new pack series, Osprey UNLTD.
The Fitscape Lumbar from 3D printed fittings is the firm's second product, and it was developed to deliver superior ventilation, fine-tuned cushion support, and an anti-slip surface grip to keep possessions in place over the course of a long day.
The use of DLS 3D printing has opened up the use of materials that have previously been inaccessible to the pack industry, and it shortens development periods using conventional manufacturing methods.
“Osprey UNLTD is the manifestation of Osprey’s approach to innovation,” said Rob BonDurant, VP of Marketing at 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.”
Carbon’s DLS technology
Carbon's DLS 3D printing process, which employs digital light projections in combination with oxygen-permeable lenses to cure photopolymer resins into three-dimensional structures, is an SLA technology. The company's equipment use materials with heat-activated programmable chemistries to create parts with engineering-grade mechanical properties and high-resolution features.
The M Series is Carbon's top-of-the-line product line, comprised of the M1, M2, and most recently released M3 and M3 Max 3D printers. The newest additions deliver improved print speeds, bigger build volumes, and higher-quality components over their predecessors, and are suitable for a wide range of fields including automotive and life science to dental and consumer goods.
The same dynamic material that's used in the company's lightweight shoes is also utilized in high-performance running and sports footwear. For example, Adidas has employed DLS technology to create its 3D printed 4D midsole, the 4DFWD, which was released to the public in August 2021. DLS 3D printing technology has also been used by cycling equipment manufacturer fizik to create its Adaptive 3D printed bike saddle, and by bicycle maker Specialized for its own 3D printed bike seat.
The firm is always evaluating new possibilities to broaden its material palette and applications in sectors with growing adoption of additive manufacturing, such as medical.
3D printing backpacks with Osprey
The Osprey Fitscape Lumbar is the newest consumer goods use of Carbon's DLS technology, with the company claiming to be the first backpack manufacturer to utilize DLS technology to enhance its products.
A lumber pack distributes all of its weight directly onto the user's hips and skeletal structure to relieve stress on the back. Since 2016, Osprey has been developing a new UNLTD series' optimized lunar pad, and one of Carbon's DLS features has helped to make this possible.
3D printing the Fitscape Lumbar has improved ventilation and fine-tuned cushion support, as well as providing an anti-slip surface to better keep loads in place, according to the company. The rear of the lumbar is formed from a polycarbonate vacuum-formed framesheet with thermo-formed air channel ribs on the backpanel to improve support, fit, and ventilation.
Osprey's use of additive manufacturing in the production process has also aided in lowering waste throughout the manufacturing process and speeding up product time to market.
“Traditional manufacturing methods teach us that in order to push the boundaries of innovation, product development timelines need to be extended,” said Phil DeSimone, Carbon Co-founder and Chief Product and Business Development Officer. “The development of Osprey UNLTD proved the exact opposite.
“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.”
The UNLTD backpack series, which is made with 3D printing, includes a number of helpful modifications, such as an Autolift mechanism that helps to evenly distribute the weight of the pack and a Fit-on-the-Fly adjustment for the shoulder strap. The Airporter Backpack, like all other packs in the line, is made with lightweight and robust materials such as special-treated PU leather. It also has a deluxe nylon rain cover and a custom Airporter Cover with lockable zippers for safe transportation during transit.
The Osprey UNLTD is available in four versions: the Airscape 68 and Anti-Gravity 64, both of which are designed for men and women.