Design & development of the Gelert Shadow trekking pack range. Launched 4 sizes from day use to multi day (35L, 45L, 55+10L and 85L+ variants), from concept through to production-ready specification and prototype refinement. The Shadow rucksack is still on sale in 2025 through Sports Direct.
The Shadow packs were built around practical trekking needs: stable load carry, adjustable comfort, wet-weather protection, and simple organisation. The 60L version features lightweight aluminium support staves, integral rain cover, a base compartment with divider, and walking pole / ice axe attachment, plus an expandable lid and air-channel padded back panel.
The challenge was to deliver a pack that looked and felt technical while remaining viable for cost-sensitive retail. We focused on the fundamentals fit, carry comfort, robustness, and feature clarity. We then engineered the patterns, component set and construction so it could be manufactured reliably at scale.
