In this episode, I had the pleasure of chatting with Alex Rich from Mystery Ranch, a brand known for building long-lasting rugged backpacks for military personnel, hunters, and backpackers. We explore the evolution of Mystery Ranch, the nuances of backpack design, and the innovation behind their signature features. Alex shares unique insights into the materials, design processes, and philosophy that shape Mystery Ranch's approach to making products that truly "make it suck less." 

Key Takeaways

• Starting from the user: Mystery Ranch's design philosophy always begins with how the pack interfaces with the user, focusing on comfort and load distribution.

• Overload system innovation: The company’s overload system revolutionized hunting packs by allowing users to separate the pack from the frame for carrying additional weight.

• Balancing weight and durability: Mystery Ranch intentionally adds weight to certain parts of the pack to improve structural integrity and comfort for heavy loads, though they are exploring lighter materials like the 330D fabric.

• Foam design for durability: The waist belts of Mystery Ranch packs use a combination of five different types of foam to ensure long-term comfort and support, even with heavy loads.

• Adapting military pack designs for hunters: Mystery Ranch's transition from military to hunting packs was organic, with their military-grade designs proving useful for outdoor applications.

• Evolving materials: The conversation highlights how new materials, such as 330D fabrics, are pushing the boundaries of outdoor gear design.

From Production Floor to Design Lead

Alex’s journey with Mystery Ranch started over 12 years ago on the production floor, sewing backpacks. It wasn't long before his curiosity and initiative caught the attention of the company. He worked on personal projects after hours, experimenting with different designs, which led to opportunities in engineering and eventually a full-fledged role on the design team.

Alex now focuses primarily on the hunting line of products, but his background spans military, outdoor, and firefighting packs, giving him a comprehensive perspective on carrying solutions. This wide exposure has allowed him to witness firsthand the unique needs of each customer base and how they influence design decisions.

Mission vs. Outdoor: Designing for Specific Needs

One of the core themes of our conversation was the difference between Mystery Ranch’s mission-driven products—targeted at military and firefighting needs—and the packs designed for hunting and outdoor activities. According to Alex, the mission line often involves designing to strict specifications, such as carrying specific equipment like mortar base plates or drones. In contrast, the hunting and outdoor lines are driven by the customer’s need for versatility, allowing them to carry both initial gear and heavy loads, such as elk quarters, on the return journey. This led to the development of their signature overload feature—a system that separates the bag from the frame to carry extra load efficiently and close to the body.

The Overload System: A Game-Changer

The overload feature was a pivotal moment in Mystery Ranch's design history. Initially developed for military packs, the idea was inspired by soldiers struggling to carry heavy mortar base plates strapped far from their bodies. This setup created a physics problem, making the load feel even heavier. Dana Gleason, the founder, rethought this approach by bringing the load closer to the user's body, improving ergonomics and comfort.

This innovation later found a natural fit in the hunting community, where hunters needed similar load-carrying capabilities for packing out meat. Alex explained that by separating the bag from the frame and creating a space to secure the extra load, Mystery Ranch was able to meet the hunters' needs effectively. “There’s the load, then there’s the overload,” Alex noted, highlighting the dual-purpose nature of these packs.

Flexibility in Design: The Pop-Up Frame

One of the standout innovations that Alex shared was the development of the Mystery Ranch Pop-Up frame. This telescoping frame can be compacted when not needed, providing hunters with flexibility while navigating dense environments or crouching. But when the time comes to haul heavy loads, the frame extends, providing optimal support for the extra weight.

Interestingly, the initial idea faced resistance, but Alex persisted, pitching the idea to Dana directly. Now, the pop-up frame is one of their best-selling packs. Its versatility has even led to surprising applications beyond hunting, such as pack rafting, proving its adaptability and usefulness.

The Importance of Fit and Load Carriage

Alex mentioned that the Mystery Ranch design process always begins with the connection points—how the pack interacts with the user’s body. From robust waist belts that don't fold under pressure to yokes that adjust for different torso lengths, every element is considered to make heavy load carriage more manageable. The waist belt, in particular, plays a critical role in stabilizing the load, preventing uncomfortable twisting or collapsing under strain.

Material Innovations and the Future

We also discussed recent material advancements, including a shift from traditional 500 denier Cordura to a lighter but equally durable 330 denier fabric. This shift allows Mystery Ranch to reduce pack weight without sacrificing strength or reliability, addressing one of the common critiques that their packs have been a bit on the heavier side compared to competitors.

Beyond fabrics, Alex discussed their use of different types of foam in their waist belts to balance comfort and durability. The hunting waist belt alone contains five different densities and types of foam, layered to provide structure, comfort, and resilience over long periods of use.

The Mystery Ranch Commitment

Talking with Alex offered a glimpse into the depth of thought and iteration that goes into every product at Mystery Ranch. Their commitment to building packs that can handle the demands of military missions, rugged hunts, and outdoor adventures alike is evident in every stitch and strap. The focus is always on making the experience "suck less"—a mantra that resonates through their product lines, whether it's making the toughest military tasks more bearable or helping hunters pack out with confidence.

For those of us who depend on our gear to perform in the backcountry, it's reassuring to know that people like Alex are behind the designs—people who care about every detail, test every limit and push for constant improvement.

Emory, By Land

Thanks for stopping by! If you have any questions for me or want to connect, you can leave a comment below or shoot me a personal message at emory@byland.co.

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