Innovating Backpacking: A Plastic-Free Expedition

Professor Tom Bonamici embarked on an ambitious year-long project to construct a 10-pound backpacking setup composed entirely of natural materials. His innovative approach sought to challenge the outdoor industry's reliance on petrochemical-based synthetics like polyester and nylon. By meticulously crafting items such as a wool and silk sleeping quilt, a linseed-oil-treated silk taffeta tarp, bamboo trekking poles, and a range of custom clothing from natural fibers, Bonamici aimed to explore the practical compromises and benefits of a fully compostable gear system. This academic endeavor, funded by the University of Oregon, pushes the boundaries of sustainable product design in the realm of outdoor equipment, with his collection slated for exhibition at Dutch Design Week.

Working from his studio at the University of Oregon in Portland, Bonamici's primary goal was to investigate the performance disparities between conventional synthetic outdoor gear and their natural counterparts. He acknowledged the superior lightweight, waterproof, and durable qualities of synthetic materials but expressed a keen academic interest in understanding the implications of their complete exclusion. His exploration involved everything from hand-sewing merino wool long johns to commissioning specialized wool socks and handcrafted shoes, ensuring every component, including straps, fasteners, and food containers, met the plastic-free criterion. The only exceptions were his water filtration system and first-aid kit, which he deemed essential for safety.

Bonamici's background as a product designer and woodworker, combined with his passion for the outdoors cultivated since childhood, informed this project. He previously co-founded Archival Clothing, a brand known for its heritage apparel made from cotton canvas and vintage hardware. His recent foray into plastic-free gear culminated in a field test on Mt. Hood. Among the key items, his ultralight backpack, crafted from densely woven cotton and merino jersey with aluminum hardware, showcased the potential for natural materials in structural components. The initial stiffness of the merino felt shoulder straps gradually conformed to his body, though he noted some tactile issues with cotton webbing and metal cord locks, suggesting areas for design refinement.

The shelter, a 9-foot tarp made from oiled silk taffeta, demonstrated remarkable water resistance, shedding water effectively even after prolonged exposure. This ancient sailing material proved lighter than many modern synthetic shelters, weighing just 25 ounces. Reinforcements at high-stress points using double stitching and cotton tape ensured its integrity during testing. Bonamici's sleeping quilt, featuring a silk-cotton blend shell and Lavalan wool batting insulation, offered a luxurious and warm experience, albeit with a noticeable weight penalty compared to synthetic alternatives. The minimalist sleeping pad, designed more for thermal insulation than comfort, highlighted significant compromises in cushioning, weighing nearly twice as much as a conventional ultralight pad.

For trekking poles, Bonamici opted for Calcutta bamboo, a robust species historically used in other outdoor equipment. He fitted them with aluminum and carbide tips, though he recognized the limitation of non-adjustable poles and the need to improve the hand straps for enhanced durability and comfort. His custom apparel, including a soft-brim hat, cotton shorts with a merino wool gusset, various merino and silk hoodies, and a Ventile anorak, all proved exceptionally comfortable and functional in fair weather. The qiviut wool sweater, in particular, stood out for its warmth. However, the cotton shorts' slow drying time after a river dip indicated a potential area for material substitution in future iterations. Lastly, his handmade hiking shoes from FEIT, constructed from natural components like vegetable-tanned leather and natural latex rubber soles, were found to be bulky and required a significant breaking-in period.

Following initial tests of his comprehensive natural-material backpacking kit, Professor Bonamici expressed satisfaction with the overall performance, particularly the comfort of the clothing and the unexpected durability of all components. The favorable summer conditions in the Pacific Northwest undoubtedly contributed to the successful outcomes. He is now keen to delve deeper into material science, planning further laboratory tests on the oiled-silk tarp to optimize fabric, oil compositions, and seam designs for improved strength and water resistance. While he looks forward to returning to his familiar synthetic trail runners and inflatable sleeping pad for certain comforts, he intends to integrate his handcrafted, plastic-free apparel into his regular outdoor routine, underscoring its impressive comfort and functionality.