Hiking & Trekking Jackets
A hiking jacket is judged on weight and packability more than any other spec. Our shell programme runs from an 80 gsm 3L tricot that packs into its own pocket up to a 200 gsm 3L built for multi-day loads, all fully taped and tested to ISO 811. Whether you need a 10K/10K entry shell for a value range or a 20K/20K for alpine use, the construction is the same process — only the specification changes.
Hiking shell constructions we run
Four constructions cover the hiking and trekking market from entry price to technical premium.
2.5L packable shell
80-110 gsm, printed or embossed backer instead of a lining. Lightest and most packable.
3L hardshell
145-200 gsm with a tricot backer, fully taped. The multi-day and alpine standard.
2L lined shell
With a mesh or taffeta lining. More affordable, slightly heavier, easier to repair.
Stretch softshell
Bonded stretch face with fleece back, for dry cold and high-output days.
Hiking fleece midlayer
Grid or anti-pill fleece 200-300 g/m², designed to layer under the shell.
Hiking rain poncho
Oversized cover-all shell, popular for trekking and festival ranges.
Specification by price point
Where brands most often overspend or underspec. Use this as a starting point for your range architecture.
| Entry (value range) | 2.5L, 80-100 gsm, 10K/10K, taped seams, basic coil zips |
|---|---|
| Mid (core range) | 3L, 140-160 gsm, 15K/15K, YKK zips, pit zips, adjustable hood |
| Premium (technical) | 3L, 180-200 gsm, 20K/20K or higher, AquaGuard zips, helmet-compatible hood |
| Packable / emergency | 2.5L, 80 gsm, 10K/10K, packs into pocket, minimal feature set |
| Alpine / expedition | 3L, 200 gsm+, reinforced shoulder and hip for pack abrasion |
Construction details that decide the review score
Three details separate a shell that gets returned from one that gets recommended.
Seam taping, not fabric rating
Water enters a jacket at the needle holes, not through the membrane. A 20K fabric with badly applied tape will leak before a 10K fabric with good tape. We tape every seam on waterproof styles and test the finished garment, not just the fabric swatch.
Hood that works with a pack
A hiking hood has to move with the head and clear a pack collar. We test hood volume over a loaded pack rather than on a bare mannequin, and use a three-point adjustment so the hood tracks the head without pulling the collar across the face.
Pit zips and pocket placement
Pit zips need to clear the pack hip belt or they are useless. Chest and hand pockets need to sit above the hip belt too. We check pocket and vent positions against a loaded hip belt during fitting, which is where most OEM shells quietly fail.
- YKK coil or AquaGuard zips, with storm flaps on premium styles
- Adjustable cuffs that seal over a glove without a velcro-heavy look
- Drop-tail hem set from a loaded-pack stance, not a standing one
- PFAS-free C0 DWR as standard
Fabric and testing
| Face fabric | Polyester or polyamide 20D-75D, ripstop or plain weave |
|---|---|
| Membrane | TPU or ePTFE; 2L, 2.5L or 3L |
| Weight range | 80 gsm to 200 gsm |
| Ratings | 10K/10K, 15K/15K, 20K/20K |
| Backer | Tricot, printed, embossed or mesh |
| DWR | PFAS-free C0 standard |
| Recycled | GRS-certified recycled polyester available |
| Testing | ISO 811 hydrostatic head on every waterproof run, records per batch |
MOQ, sampling and lead times
| MOQ | 400 pcs per colour, sizes mixed within the colour |
|---|---|
| Sampling | 7-10 days in stock fabric, 15-20 days if fabric must be sourced |
| Bulk lead time | 35-55 days after PP approval |
| Quote turnaround | Within 24 hours |
Questions buyers ask
What is the lightest hiking shell you can make?
Around 80 gsm in a 2.5L construction with a printed backer — roughly 250-300 g finished weight in a men's medium, packable into its own pocket.
Do you test every waterproof batch?
Yes. Every run is tested on a calibrated hydrostatic head tester to ISO 811 and the records are kept per batch. Taped seams are checked separately.
Can we get recycled fabric?
Yes. GRS-certified recycled polyester in most weights we run, with transaction certificates issued against your order.
What is the MOQ for custom hiking jackets?
400 pcs per colour with sizes mixed inside that colour. Styles sharing one fabric platform can often share the minimum.
Is the DWR PFAS-free?
C0 PFAS-free DWR is standard. If you need a specific chemistry for an EU market or retailer RSL, tell us when quoting.
Can you build a shell around our own fabric?
Yes. We run CMT and semi-CMT programmes where you nominate or supply the fabric. We still inspect incoming fabric before cutting.
Tell us what you need
Send a tech pack, a reference sample or just a target price. We reply within 24 hours with a fabric suggestion, a cost indication and a sampling plan.
Get a quote