Captain's Duffel
An independent study in soft goods design and manufacturing.
The Captain’s Duffel is a rugged equipment bag designed specifically for ultimate frisbee coaches and captains.
This project aimed to practice designing a product from a defined brief while working within the strict visual language of a brand: in this case, Salomon.
The end-to-end process included user research, pattern drafting, sewing, and field testing, culminating in a full tech pack and manufacturing plan.
Year
2025
Timeline
20 Weeks
Designer
Liam Reese
Contribution
Project Lead
Industrial Design
Pattern Drafting
Tech Pack
Color, Material, and Finish
Design for Manufacture
User Testing
Marketing
Branding
Photography
An all-in-one solution to transporting ultimate frisbee equipment.
Combining the utility of a duffel with the carry comfort of a backpack, this bag is a single, game-day-ready solution for cones, jerseys, medkits, discs, and coaching gear.
Carbon-Concious Material Choice
Built from recycled fabrics and hardware, the Captain’s Duffel reflects Salomon’s commitment to sustainability—minimizing environmental impact without compromising performance or durability.
Features
01
Design Process
A 20-week design sprint modeled after real-world workflows.
Project Roadmap
Research & Ideation
Ideation began with research into current solutions and design trends, guided by Salomon's past and current products. From there, explorations via sketching followed, honed by specific design details.
Pattern Drafting
Custom patterns were developed from scratch, iterated through multiple rounds of prototype testing, and digitized using TukaCAD software. These patterns were developed from paper models through 3 integrated prototypes.
Prototyping
The prototyping process was iterative. Models and versions were sewn by hand and tested extensively.
Branding & Marketing Content
The final bag was presented through studio photography and branded visuals mimicking Salomon’s outdoor campaign style. A gritty, athletic tone was used to capture the spirit of ultimate frisbee while fitting into the brand’s visual identity.
02
Tech Pack
The final prototype was translated into a full production-ready tech pack.
Illustrations
Colorways
Eight brand-aligned colorways were developed for launch. These palettes reflect Salomon’s 2025 identity while introducing new colorways for the Ultimate Series product line. Multiple colorways were necesarry to help the bag stand out on the sidelines and in travel.
Pattern
All pattern pieces were digitized using industry-standard software and laid out for efficient cut and kit processes. The full-scale files are optimized for CNC cutting and labeled for assembly.
Label Requirements
Legal and care labels were designed according to global regulations, along with custom Salomon hangtags and woven brand labels.
Assembly Instructions
A detailed step-by-step sewing guide was created to ensure consistent assembly and streamline communication with manufacturers. The instructions include part references, construction order, stitch types, and alignment tips.
View the full instructions here:
View PDF
Bill Of Materials
Every component—from textiles and hardware to foam and thread—was selected for durability, weather resistance, and compatibility with Salomon’s sustainability initiatives. Total material cost per unit: $34.44.
03
Manufacturing Plan
To prepare the Captain’s Duffel for scalable production, a full manufacturing strategy was developed. This included cost modeling across global production hubs, landed cost calculations, and factory-ready documentation.
Manufacturing Location - Mexico
Production costs were analyzed across five countries. Mexico was selected for its balance of low labor rates, proximity to North America, and manageable freight costs. Tariffs and roll-up costs were factored into final unit pricing.
Per Unit
$34.44
Materials
1:15
Work Hours
$6.25
Labor
$0.60
Freight
Retail
$42.86
Roll-Up Cost
$230
Retail Price
81.37%
Margin
Landed Cost
With materials, labor, and shipping considered, the roll-up landed cost allows for a profit margin of 81.37%, enabling premium positioning and brand-aligned pricing.
Marking Layout
Fabric utilization was optimized through detailed marking layouts for each material. Yields and roll widths were carefully calculated to reduce waste and meet sustainability targets.
04
Full Report & Tech Pack
View the full process documentation here: