One299 Adjustable Pack Frame

An external backpack frame that easily adjusts to conform to the user’s size and shape

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The world’s first adjustable external backpack frame

One299 was designed to meet the changing needs of the Australian Defence Force, by providing a high-load backpack frame that is adjustable to correctly fit the back of 1-percentile to 99-percentile female and male users. Through extensive strength testing, anthropometric analysis and iterative load simulation, Cobalt was able to meet and exceed military expectations and outperform existing fixed-size frames.

In addition to size adjustability, a key element of ONE299 is the patented lumbar area which conforms to the contour of the wearer’s back. This allows for a superior ergonomic fit as well as increased load.

The use of a correctly fitting frame reduces the potential for back injury, and the One299 frame offers this to all wearers regardless of size. Its high strength and adjustable nature also create new opportunities for load carriage configuration, allowing both the frame and the backpack to be adjusted and configured to suit alternative load carriage scenarios.

More than 27,000 frames have been deployed in the Australian Defence Force, with additional interest from international military groups and adventure sectors proving a great commercial outcome.

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2016 Land Defence Australia Innovation Award

Focus Areas

Human Factors and Ergonomics
Industrial Design
Product Engineering
Analysis and Simulation
Prototyping
Testing and Evaluation
Tooling Support
Animation and Product Visualisation

Year

2015

Client

Australian Defence Apparel

One299 image demonstrating possible height adjustment options to suit the user.

Side view of two One299 Pack Frames, showing the height adjustability of the unit.

Design Outcomes

Versatile

Ergonomic

Adjustable

Compatible

Robust

The One299 pack frame has been successfully designed to meet a wide range of user demographics. Human factors engineering methods and an innovative adjustment mechanism were combined to ensure the pack frame can be used across 1st to 99th percentile male and female users.

An innovative lumbar support device makes the One299 pack frame comfortable for all users across a range of load carriage scenarios. The shape and form of the frame were carefully developed to create a 3D countering that conforms to all body shapes and sizes.

Constructed of only two single high-strength polymer mouldings, the One299 pack frame features a simple and secure adjustment and locking mechanism. Adjustment does not require any tools, allowing fast and easy adjustment in the field.

The One299 pack frame was designed to be compatible with a range of in-service or industry standard pack and harness systems, making the system suitable for retrofit onto exiting packs in service or specified for future defence supply contracts without customisation.

The One299 pack frame was designed to meet significant load rating and cycle testing requirements. Through iterative engineering, advanced FEA and real-life testing, the frame design was refined to minimise bulk and weight while ensuring optimal lateral and torsional stiffness characteristics were achieved.

The Team We believe good design happens by expert people working as a team.

Libby Christmas

Graeme Marshall

Andrew Fanning

Marcus Krigsman

James Hayes

Rob Cuzner

Chris Morrish

Defence force soldier wearing backpack with One299 frame, crouched on one knee looking into the distance.

In-depth analysis of use scenarios and user anthropometry formed the basis for the design, while iterative testing and simulated analysis (FEA) provided a detailed understanding of performance under load. These functional targets were achieved within a compressed development program, with design and engineering teams working in partnership with local manufacturers to ensure the client’s performance and commercial targets were met.

Finite Element Analysis (FEA) was used extensively throughout this project, allowing the design and engineering team to compare the design to real-life testing.

We at Cobalt were also able to refine details to achieve maximum strength in excess of an 80kg working load, while also improving user comfort through specifically targeted flex areas. As part of an iterative process, this simulation led to an end result optimised for strength, weight, manufacturability and user comfort. It also achieved the previously unrealised universal anthropometric and ergonomic targets. Extensive in-house physical testing and Australian Defence Force field trials provided input and feedback during development and validated the strength, comfort and usability outcomes of the final product.