Why HDPE Flashspun Fabric?

Choosing to use HDPE flashspun fabric in the manufacture of our Cowboy Camping products was a foundational decision for the brand. Because of that, it’s important to us that our users understand the material, including its pros and cons and its history in the DIY ultralight community. So without further ado, let’s get into how HDPE flashspun fabric is made, where you’ve likely seen it in the world, and the benefits of using it for outdoor gear.

How is HDPE flashspun fabric made?

Flashspun fabric isn’t made by sewing or weaving. Instead, its structure is created from a multitude of overlapping HDPE filaments. It’s manufactured by dissolving HDPE in a solvent, heating it under high pressure, and then extruding it into a low-pressure chamber. The solvent immediately evaporates, leaving behind a network of extremely fine, overlapping filaments that bond into a nonwoven sheet.

This random, interconnected structure makes the material highly resistant to tearing. Despite being unwoven, it can still be cut, sewn, and used much like traditional fabric.

How is HDPE flashspun fabric used?

Historically, HDPE flashspun fabric is best known for its use as homewrap, where it provides a reliable and efficient way to protect building walls from the elements - the most well known product is Tyvek, manufactured by DuPont. It’s also widely used in PPE due to its pore structure - air can pass through, while liquids, bacteria, and viruses are blocked. Because it can be easily printed on, it’s also commonly used for banners, signage, and packaging.

Why use it to make outdoor gear?

We’re not breaking new ground here - HDPE flashspun fabric has been used in outdoor gear for years, just not widely within the traditional outdoor industry. Industrious ultralight backpackers have long purchased Tyvek sheets from hardware stores to use as DIY groundsheets, and some industrious makers have even sewn it into stuff sacks and other storage solutions. It’s a convenient DIY material because it doesn’t fray when cut, unlike many woven fabrics.

It’s also highly effective for outdoor gear: it’s water-resistant, tear- and abrasion-resistant, and - best of all - extremely economical. It’s more affordable and more tear-resistant than Dyneema, and it doesn’t absorb water the way SilNylon does. An added bonus is that it can be easily and durably written on with Sharpie, allowing for hikers to easily throw together a hitching sign if need be.

While we encourage DIYers to keep doing their thing, not everyone has the time, tools, or experience to sew their own zip cubes, stuff sacks, or wallets. Beyond that, Tyvek can’t be cut as wide as our Pardner Pad - commercially available rolls aren’t wide enough. Cowboy Camping offers ready-to-go accessories and extra wide groundsheets - helping newer backpackers discover this material sooner, or giving experienced backpackers a wider array of options for using the material than a one person groundsheet.