TUFA / Materials / Kalispell, Montana
Exceptional materials.
Understood from the inside.
TUFA design starts with a materials-first approach. Our edge is a deep knowledge of technical textiles and materials—and how to combine them to create world-class products.
The experience behind the choicesChallenge Sailcloth
Product Development & Global Sales
A hand in development.
A view across the industry.
At Challenge Sailcloth, I worked under Hale Walcoff to help build the Challenge Outdoor program. My role spanned product development and global sales, helping develop advanced technical textiles and working with brands across nearly the entire global outdoor industry.
That work drew on a deep understanding of fibers, dyeing, weaves, coatings, and lamination—and how these decisions work together to shape a finished textile. I helped designers and product teams understand the capabilities of these materials, select them for specific applications, and approach construction in ways that made the most of their properties.
At TUFA, that knowledge connects textile development directly to the cutting table and sewing machine. I choose materials with an understanding of how they are made, where they excel, and where their limitations lie. It allows me to make deliberate choices about weight, durability, weather resistance, and feel—and build each product to take full advantage of its materials.
01 / Technical Textiles
Technical Textiles
Our equipment is built with advanced technical textiles, including composites Josh helped develop during his work at Challenge Sailcloth.
Ultra fabrics, by Challenge Sailcloth, are the foundation of our product line. Built around UHMWPE fiber, Ultra delivers exceptional tear and abrasion resistance at remarkably low weight, with a waterproof laminate construction that maintains structure under load.
02 / Zippers
YKK Zippers
We use YKK AquaGuard® zippers throughout our equipment for their proven reliability, clean operation, and weather resistance.
AquaGuard pairs YKK’s dependable zipper construction with a polyurethane-coated tape that helps shed rain, snow, and moisture without the bulk of a traditional storm flap. The result is a low-profile closure that performs exceptionally well in harsh environments.
Zippers are one of the most common failure points in outdoor equipment. We don’t cut corners on them.
03 / Hardware
Trimmers Hardware
We use Trimmers aluminum hardware - the most refined pack hardware in the world. It is exceptionally light, remarkably strong, and built to survive the kind of abuse that can destroy molded plastic buckles: being stepped on, crushed under gear, or caught in a car door.
Most outdoor brands use plastic hardware because it works - and because it is cheap. The aluminum hardware we use can cost more than 10× as much. We use it anyway because it feels better, lasts longer, and belongs on equipment built without compromise.
04 / Webbing
Webbing
Webbing looks simple, but its weave, stiffness, strength, and hand feel have an enormous effect on how equipment performs.
We use mil-spec technical webbing for structural applications where strength, abrasion resistance, and long-term reliability matter most. For select adjustment points, we use BioThane® coated webbing, which provides a rubberized feel that is easier to grip and manipulate with gloves, while also resisting moisture and grime.
Every webbing is chosen for its specific job—whether it needs to carry load, move smoothly through hardware, hold an adjustment securely, or remain easy to operate in cold technical environments.
05 / Foam
Technical Foams
Foam is one of the least visible materials in a pack—and one of the most important to get right.
We use carefully selected technical foams to create structure, distribute pressure, and provide cushioning without unnecessary bulk or weight. Density, rebound, thickness, and stiffness all come together to create an incredibly comfortable and responsive pack harness.