Fabrics

Every pack is built with Challenge Sailcloth Ultra fabrics. We chose these over lighter alternatives because they last — high tear strength, serious abrasion resistance, and construction that holds up season after season. Sufficiently light, genuinely durable. You choose the fabric for each section of your pack, so you can dial in the right balance for how you actually use it.
Ultra 200
Grey
Challenge Ultra200X
Lightest Option

200d Ultra-PE face blended with high-tenacity polyester, Ultra-PE CrossPly, and 0.75 mil film backing. At 3.9 oz/yd² it exceeds the technical properties of any similar-weight fabric available. Exceptional tear strength and solid abrasion resistance for its weight — the choice when every ounce counts.

Weight
3.9 oz/yd² (133 gsm)
Tear Strength
Warp 103 lb / Fill 133 lb
Abrasion
4,400 cycles
Best for: Builds where weight matters and terrain is managed carefully. Main body when you want the lightest option without sacrificing strength.
Ultra 400 TX
Black
White
Challenge Ultra 400 TX
Maximum Durability

Twice the abrasion resistance of the Ultra200X at 8,800 cycles, with significantly higher tear strength. Built for hard use — cross-country scrambling, granite slabs, heavy loads, rough country. If you're going to push your pack through serious terrain, build the high-wear areas with this.

Weight
7.2 oz/yd² (244 gsm)
Tear Strength
Warp 188 lb / Fill 161 lb
Abrasion
8,800 cycles
Best for: High-wear areas — pack bottom, front panel, water bottle holders — or full builds meant to take a beating season after season.
Ultra Grid
Black
White
Challenge Ultra Grid
Recycled + Waterproof

Recycled 210d nylon woven with a 5mm double 200d Ultra grid, C0 DWR finish, and 1500mm PU waterproof coating. The only fabric in the lineup with a rated hydrostatic head — it won't absorb water. Tear strength is off the charts (the fabric simply doesn't tear in testing). Abrasion resistance is lower than the pure Ultra fabrics, so it's best suited for main body and trim work rather than high-abrasion contact zones.

Weight
4.3 oz/yd² (146 gsm)
Tear Strength
Does not tear
Abrasion
1,100 cycles
Waterproof
1500mm hydrostatic head
Construction
Recycled 210d nylon + 200d Ultra grid
DWR
C0 (PFAS-free)
Best for: Builders who prioritize sustainability and waterproofing. The only option for water bottle holder trim and front panel trim accents.
Side by Side
Fabric Weight Abrasion Resistance Strength Sustainability
Ultra200X
Lightest — 3.9 oz/yd²
4,400 cycles
Excellent
Standard
Ultra 400 TX
Heaviest — 7.2 oz/yd²
8,800 cycles
Excellent
Standard
Ultra Grid
4.3 oz/yd²
1,100 cycles
Does not tear
Recycled + Waterproof

Not sure which fabric is right for your build? Reach out — happy to talk through it based on where you're going and how hard you push your gear.

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