Dyneema DCF: a gear maker’s guide

01 / The material

What is Dyneema DCF?

Dyneema Composite Fabric, usually shortened to DCF, is a laminate. In its familiar lightweight form, very strong Dyneema fibres sit between thin polyester films. The fibres carry the load; the continuous film provides the waterproof barrier. It is a different construction from the woven nylon and polyester fabrics used in much outdoor gear.

From racing sails to lightweight packs

The story starts with Dyneema, a brand of ultra-high-molecular-weight polyethylene, or UHMWPE. Its development at DSM began in the 1960s.

The sailcloth later known as Cuben Fiber emerged in the early 1990s. Its name is associated with America³, pronounced “America Cubed”, the yacht that won the 1992 America’s Cup. Racing sails needed high strength and low weight, with very little stretch. Those qualities later caught the attention of lightweight gear makers. DSM acquired Cubic Tech in 2015, and the material became known as Dyneema Composite Fabric.

Why is it so light?

Dyneema fibres get their strength from very long molecular chains lined up tightly together. That lets a thin, light sheet of DCF carry a surprising amount of load. It is one of the reasons it became so popular for lightweight shelters, pouches and packs.

A pair of ultralight DCF gaiters - weighing just at 48g

Why is it waterproof?

Dyneema fibres absorb virtually no water, but the waterproof barrier in standard DCF is the continuous film surrounding them. It does not rely on a water-repellent surface treatment to keep rain out.

The seams and closures still need to keep water out, and holes in the film can cause leaks. DCF does not breathe, so you can still get condensation inside a DCF shelter.

02 / A maker’s introduction

How I first came across DCF

Around 2014, I came across the material on YouTube. I saw people in the US making their own pouches and shelters with Cuben Fiber, and gradually learned about MYOG: “make your own gear”.

One of my most direct influences was the Ray-Way backpack. Ray Jardine, the author of The PCT Hiker’s Handbook, was an important figure in lightweight backpacking, and his approach made an impression on me. Yamatomichi’s MINI is another example of that influence: the brand describes it as inspired by the Ray-Way backpack.

We chose DCF because some of the products we wanted to make suited it well. For other products, nylon made more sense, so we used nylon. Sometimes offering a DCF version simply gives people another useful choice. Making something people want to use is one of the things that keeps us going.

If a product suits nylon, we use nylon. The choice of material comes from what the product needs to do.

Shan Feng

03 / Comparing materials

DCF, nylon and polyester

Here is how I think about the main trade-offs when choosing a fabric. More filled stars means a better fit for that quality.

A rough guide; grades and finishes vary. Nylon and polyester ratings assume a waterproof coating or membrane.

Where DCF needs care

DCF is strong when pulled, but its thin outer film is more vulnerable to rubbing and sharp points. A thorn or rough rock can make a hole even when the fibres are still holding together. Over time, worn areas can also start to separate between the layers.

That is why we think carefully about where to use it. A light pouch inside a pack has a very different life from the base of a backpack being set down on rough ground.

04 / Matching fabric to use

Standard DCF, hybrid DCF and fabric weights

Standard DCF is the familiar film-faced laminate, often translucent. Its very light grades are useful for shelters and small accessories where keeping weight down matters.

Hybrid DCF, often called DCH, adds a woven face fabric to the laminate. That extra face improves resistance to abrasion and gives the fabric a different feel. It also adds weight, which can be a sensible trade-off for a backpack.

You will often see DCF described in oz/yd². This is the fabric’s weight per square yard: a higher number usually means a heavier grade.

How we use it in the FAST30

For our FAST30 product, we use lighter DCF or hybrid DCF for the body and tougher, 5.1 oz/yd² hybrid fabric at the base. It is a simple idea: keep the weight down where we can, and add protection where the pack meets the ground.

05 / Two PPU designs

A pillow and a pair of gaiters

These two products show different sides of our approach: making one item serve more than one purpose, and deciding whether a material’s advantages are worth its limitations.

The Merino Pillow

The Merino Pillow is one of my personal favourites, especially for longer walks. It will not suit every hiker, but some people become very attached to it once they have used it.

It is a straightforward example of carrying one thing for two jobs. During the day it is a storage pouch; at night, you can fill it with spare clothing to make a pillow. The sleeping surface is 100% merino wool, chosen for its comfort against the skin and its natural resistance to odour.

We added a strap to help keep it on the sleeping mat and stop it sliding around. I also like this product because of the care that goes into making it

View the PPU Merino Pillow at Tanwa Outdoor

The Hiking Gaiters

The gaiters are a more debatable choice. We knew from the start that standard DCF had limited abrasion resistance. Using it for something worn close to the ground meant accepting a compromise.

We still chose it for its low weight, its waterproof film and the possibility of making simple repairs. We also saw the option of reinforcing worn areas with DCH to help extend their life. Small holes can often be patched, which is useful when you are out on a longer walk.

Keeping water out was particularly important to us. The DCF panels take up very little moisture and are easy to wipe clean, which is useful in wet or muddy conditions. The material’s limits still apply: repeated contact with rocks or sharp objects can damage it.

View the PPU Hiking Gaiters at Tanwa Outdoor

06 / Limits & what comes next

Choosing materials with care

For me, the main limitation of standard DCF is abrasion. That means thinking carefully about where to use it, and choosing a hybrid construction or another fabric where more protection is needed. Its advantages are useful, but its weaknesses are just as much a part of the design decision.

Materials such as Dyneema Woven Composites, Ultra and ALUULA are giving designers more ways to balance weight and durability. They use different constructions, but all reflect the same wish for lighter gear that lasts longer.

I think the direction of development will continue to follow what people need: lower weight, better durability and a longer useful life. For many ordinary trips, we already have materials that can do the job well. More demanding environments still need particular care.

Once the practical requirements are met, appearance and personal preference have a place too. That part of choosing gear is individual.