Topic

Ultra 100 delamination

Viewing 4 posts - 1 through 4 (of 4 total)
PostedJul 31, 2026 at 11:08 am

I have several items with Ultra laminates.

I noticed fairly soon that some of my Ultra 100 (I think) pouches made a crinkling sound associated with delamination.

Sure enough, today I opened a pouch, and the inner field has completely delaminated. Not in just 1 spot, no, over  the entire fabric.

From the sound, I suspect other pouches are similar. This makes me worry my backpack made with Ultra will suffer a similar fate.

I’m not sure how old the pouch is, but it’s not that old. Similar pouches from DCF or other limited have never done this, at least, not after a fairly short time like this. Nor have other DCF items like a tent floor I have.
Extra worrying, the pouch doesn’t get wet, or exposed to sunlight. This is just from sitting and flexing.

Have others experienced similar delamination? Meaning after very short, no stress use?

PostedAug 5, 2026 at 4:04 pm

A friend of mine with an ultra 200 pack noticed a huge portion of it delaminated after 4 years but only like 6 weeks worth of trips. I was worried about ultra delamination before purchasing my latest pack. However, my concerns were alleviated after researching it a bit more. Ultra 100 and 200 did have known issues, but the latest ultra x material solved it. AI summary of the improvements:

The main difference between standard Ultra (100/200) and Ultra X (100X/200X) is the addition of a reinforcing cross-ply layer and a thicker waterproof film layer. Challenge Sailcloth engineered the “X” variants to fix the bias stretch and premature delamination issues found in the first-generation standard Ultra fabrics.

Standard Ultra 100 & 200: Consists of a 2-ply design. A woven face (66% UHMWPE / 34% polyester) is laminated directly to a 0.5 mil recycled polyester (RUV) waterproof backing film.

Ultra 100X & 200X: Upgrades to a 3-ply design. It places a diagonally oriented X-grid of Ultra 200 threads beneath the woven face, backed by a thicker 0.75 mil RUV film.

Ultra 100/200: Can stretch diagonally (on the bias) under heavy loads. This diagonal shear stress weakens the adhesive bond over time, causing the backing film to separate and bubble (delaminate).

Ultra 100X/200X: The 45° and 135° X-ply strands lock the fabric diagonally. This eliminates bias stretch and stops the shearing force that causes the laminate to peel away.

While the face fabric abrasion resistance remains identical between the two generations, the X-ply strands in Ultra X drastically improve tear strength and stitch holding under high stress.

David D BPL Member
PostedAug 7, 2026 at 10:09 pm

3 years on with my 200x backpack (Kakwa 55), guessing 10 weeks or so on it, no delam on mine.

baja bob BPL Member
PostedAug 8, 2026 at 10:48 am

Solved it is a bit of an overstatement. The X variants will delaminate.

Viewing 4 posts - 1 through 4 (of 4 total)
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