--- title: "Hyperlite Mountain Gear pushes the limits: the new Dyneema Woven Composite fabric" description: "Read about the new generation of Hyperlite Mountain Gear backpacks made from the innovative Dyneema Woven Composite material: higher durability, longer life and lower weight." canonical_url: "https://gramino.com/blog/dyneema-woven-composite-hyperlite-mountain-gear" last_updated: "2025-09-25" --- # Hyperlite Mountain Gear pushes the limits: the new Dyneema Woven Composite fabric Authors: Michaela Czempková Date: 2025-09-25 Read about the new generation of Hyperlite Mountain Gear backpacks made from the innovative Dyneema Woven Composite material: higher durability, longer life and lower weight. **Backpacks from the American brand Hyperlite Mountain Gear** have for years been among the most common backpacks used by thru-hikers on long-distance trails. Anyone who's ever hiked the Pacific Crest Trail, the Appalachian Trail, or the Continental Divide Trail has seen them on hikers' backs countless times. These are backpacks that earned their reputation through simplicity, ultralight construction, and Dyneema material – typically in white or black. Now a major change is coming. Dyneema, together with the brand [Hyperlite Mountain Gear](/b/hyperlite-mountain-gear), introduced a new fabric called **Dyneema Woven Composite** in mid-2025, promising to take the durability and lifespan of HMG backpacks to a new level. ## Properties of the original Dyneema Composite Hybrid (DCH) material Until now, HMG backpacks have been made from the hybrid composite fabric **Dyneema Composite Hybrid (DCH)**. DCH is an ultralight **laminate** made of an outer polyester or nylon fabric, a middle layer of Dyneema fibers laid in two directions (0° and 90°), and an inner waterproof polyester film. The result is a fabric that's extremely light, durable, and waterproof at the same time. The **outer layer**, however, started showing wear after frequent use. Abrasion appeared most often on the bottom of the backpack, which has the most contact with **sharp rocks and gravel**. Anyone who's used a Hyperlite Mountain Gear backpack for years knows that while the material stayed waterproof, the surface of the backpack showed signs of wear. And that's exactly what engineers at Dyneema and [Hyperlite Mountain Gear](/b/hyperlite-mountain-gear) decided to change by creating a new fabric, **Dyneema Woven Composite**. #### **What is Dyneema fiber****?** Dyneema is the trade name for **UHMWPE – ultra-high-molecular-weight polyethylene**, considered one of the strongest fibers in the world. It stands out for combining extreme tensile strength with low weight – with a strength-to-weight ratio up to **15 times stronger than steel**. It's also resistant to chemicals, UV radiation, and moisture, and has very low water absorption. Thanks to these properties, it's used not only in outdoor gear (backpacks, tents, ropes), but also in the military, aviation, and rescue equipment, where maximum reliability and lifespan at minimal weight are required. **You can read more about Dyneema material** [**HERE**](/blog/dyneema-fiber-and-its-fabrics)**.** ## What does the new Dyneema Woven Composite material bring? The new Dyneema Woven Composite (DWC) fabric has a different construction than the original. **The key difference is in the outer layer, which now uses 100% woven Dyneema instead of woven polyester or nylon**. This significantly increases resistance to abrasion and tearing. The other layers of the laminate remain the same. Tests have shown that this combination delivers up to **ten times higher abrasion resistance** and **five times higher tear resistance**, while the material keeps a low weight – it's roughly a third lighter than other high-durability fabrics. The new generation of Hyperlite Mountain Gear backpacks will specifically be made from **Dyneema® Woven Composite 3.9**. Both the black and white color options will no longer reflect a difference in fabric weight, as they used to. That means **both color versions of the backpacks will have the same durability.** ## The test results speak for themselves: - abrasion resistance is up to ten times higher - tear resistance is up to five times higher - while the fabric is roughly a third lighter than other high-durability materials ### **Properties of DWC – Dyneema® Woven Composite 3.9 (200d)** - Fabric weight: 132 g/m² - Tensile strength: 84.1 N/mm² - Tear resistance: 1112 N - Puncture resistance: 50.7 N - Water column: > 20,000 mm - [Hyperlite Mountain Gear Junction 40 (2025)](/p/hyperlite-mountain-gear-junction-40.md) - [Hyperlite Mountain Gear Junction 55 (2025)](/p/hyperlite-mountain-gear-junction-55.md) - [Hyperlite Mountain Gear Southwest 40 (2025)](/p/hyperlite-mountain-gear-southwest-40.md) - [Hyperlite Mountain Gear Southwest 55 (2025)](/p/hyperlite-mountain-gear-southwest-55.md) - [Hyperlite Mountain Gear Unbound 40](/p/hyperlite-mountain-gear-unbound-40.md) - [Hyperlite Mountain Gear Unbound 55](/p/hyperlite-mountain-gear-unbound-55.md) - [Hyperlite Mountain Gear Windrider 40](/p/hyperlite-mountain-gear-windrider-40l.md) - [Hyperlite Mountain Gear Windrider 55](/p/hyperlite-mountain-gear-windrider-55l.md) ### **Comparing DWC and DCH** ## Testing that left nothing to chance The development of this fabric took two years and involved countless lab tests – from tensile tests to tearing, puncturing, disc abrasion, all the way to simulating thousands of flex cycles in the so-called **Gelbo Flex test**. And because the lab alone wasn't enough, HMG's testers took backpack prototypes into the field – onto rocks, into the mountains, on long treks – so they could refine all the details you simply can't discover at a workbench. #### What is the Gelbo Flex test? The Gelbo Flex test is a standardized method (ASTM F392) for testing the resistance of flexible packaging materials to damage (such as tearing or puncturing) from repeated flexing, twisting, and compression. ## Which backpacks got the new fabric? So far, Hyperlite has used **Dyneema Woven Composite** on its three best-known, flagship models: **Junction**, **Southwest** and **Windrider**. ## What else has changed on the backpacks? The changes affect not just the material, but also construction details. **The back panel** now follows the body better and improves ventilation, **the shoulder straps** have a bigger curve around the neck and are wider – **making them more comfortable to wear.** There are practical updates to the pockets too: side pockets are deeper, and a lower back edge makes it easier to reach a bottle; the elastic on the top edge of the pockets is shorter and holds gear more securely, even in the large front pocket. There are also more ways to customize your backpack, whether it's **sliding the sternum strap**, simpler compression straps, or **a redesigned ice axe attachment.** You'll find changes in the details too: the backpacks got a better hydration bladder attachment, and two loops were added inside the main compartment, against the back, for attaching an optional zippered inner pocket. ### Changes at a glance: - **relocated hydration tube port** – the hydration tube opening is now located near the shoulder straps, making it more comfortable to handle - **compression straps on the sides of the backpack** – the side straps are now removable and feature a buckle for easily attaching gear - **loops** **inside the backpack** – loops for attaching an additional inner pocket - **the shoulder straps** – now better shaped (more ergonomic), wider, and adapted for longer wear - **side pockets** – deeper and more practical, so you can pull out a bottle without taking the backpack off - **daisy chain along the sides of the back pocket** – for attaching your own elastics or positioning the side compression straps to your liking - **ice axe loop** – the loop and elastic for attaching an ice axe are now located on the side of the backpack (previously in the middle) - **back panel** – better shaped so the backpack fits great and ventilates better [Video](https://youtu.be/pIqks9ZtvD0?si=EKgQgsiyqg7agbnz) ## Our experience and Gramino's take We don't yet have our own long-term experience with the new DWC fabric – DWC is a fresh novelty (since September 2025), and we haven't had a chance to take the backpacks on a trek yet. We're due for a proper field test before we can say how the new fabric holds up after hundreds of kilometers, and whether we see a difference compared to the earlier DCH material. But from what we know, this is one of the biggest innovations in ultralight HMG backpacks in recent years. We stocked the new DWC models in early September 2025, and they're already available in our [store](/b/hyperlite-mountain-gear). If you're more drawn to backpacks made from the original DCH, we've got good news for you – we now have them at a nicely reduced price. There's no need to worry that the earlier DCH models are somehow flawed or less durable. DCH is still one of the strongest and most durable fibers in the world, and we use backpacks made from it on our toughest expeditions – and as long as they hold up, we're certainly not replacing them. 🙂 - [Hyperlite Mountain Gear Stuff Sack Pillow](/p/hyperlite-mountain-gear-stuff-sack-pillow.md) - [Hyperlite Mountain Gear Pods](/p/hyperlite-mountain-gear-pods.md) - [Hyperlite Mountain Gear Bottle Pocket](/p/hyperlite-mountain-gear-bottle-pocket.md) - [Hyperlite Mountain Gear Zippy](/p/hyperlite-mountain-gear-zippy.md) - [Hyperlite Mountain Gear Camera Pod](/p/hyperlite-mountain-gear-camera-pod.md) - [Hyperlite Mountain Gear Roll-Top Food Bag](/p/hyperlite-mountain-gear-roll-top-food-bag.md) - [Hyperlite Mountain Gear Side Entry Pod](/p/hyperlite-mountain-gear-side-entry-pod.md) ## Conclusion Hyperlite Mountain Gear has shown that even a legend doesn't rest on its laurels. **Dyneema Woven Composite** is an evolution that gives backpacks greater durability, a longer lifespan, and still keeps their weight impressively low! If you're looking for a reliable partner for long journeys, the new HMG backpacks are worth a look. #### Sources: [Article](https://hyperlitemountaingear.com/blogs/the-trailhead/a-deep-dive-into-our-new-pack-fabric): Hyperlite Mountain Gear: Doubling Down on Dyneema®: A Deep Dive Into Our New Pack Fabric [Article](https://www.dyneema.com/design-with-dyneema/dyneema-woven-composites): Dyneema: Introducing Dyneema® Woven Composites This post is also available as [HTML](/blog/dyneema-woven-composite-hyperlite-mountain-gear). ## Sitemap See the full [sitemap](/sitemap.md) for all pages.