Luma Backpack

Colin Heston · CLIENT: Heston Design

Luma is a backpack made using a patented 3D knitting process that reduces material waste and simplifies production. Unlike traditional cut and sew methods, this approach produces fully shaped components directly from digital patterns with minimal waste and labor. The backpack is constructed from single strands of 100% pre-consumer recycled nylon, helping to lower energy use, emissions, and material waste. Luma's design is informed by nature and aims to offer a balance of function and sustainability through a streamlined minimalistic form.

Press Kit

Unique Properties

The Luma is a revolutionary backpack that blends sustainability, technology, and innovative design. Unlike traditional backpacks, which rely on wasteful cut-and-sew methods, Luma is created using a patented 3D knitting process. This groundbreaking technique produces seamless backpack components with little to no production waste. By condensing and optimizing the production process through automation, we are able to enhance efficiency while reducing our environmental footprint. We have created a uniquely new aesthetic that stands out from a crowded market, within a product category that has remained the same for hundreds of years. With our unique process, knit components are lighter, stronger, and more durable than traditional techniques. Each knit component is engineered with unique attributes. The shoulder straps and back panel are knit with low stretch mesh structures to disperse weight and better ergonomics, while spacer knit structures provide cushioning while remaining extremely breathable. Whereas the 3D knit main carrying compartment is engineered with no stretch and a thick 3-layer knit for durability. The main compartment also has low-melt thermoforming yarn that bonds with the nylon to add strength and structure to the form. The 3D knit structures also seamlessly integrate pocket openings and webbing for gear loops without the need to cut and sew. Thoughtfully designed to safely carry all your daily essentials no matter what environment you find yourself in.

Dimensions & Packaging

All knit components are made from 100% pre-consumer recycled nylon, cutting energy use by 45%, reducing greenhouse gas emissions by over 30%, and using 20% less water. The knit structures consist of over 1600 denier from six separate ends of nylon yarn, creating an extremely durable and lightweight 3-layer engineered knit.

Tags

3D Knitting, Sustainable, Seamless, Backpack, Accessory, Everyday Carry

Production Technology

The Luma leverages advanced 3D knitting technology to autonomously produce individual bag components directly from single strands of yarn, with zero production waste. This seamless process allows us to integrate custom features, structures, and textures into each piece, enhancing both functionality and aesthetics. By combining up to 36 different yarns within a single knit component, we can precisely tailor the material’s properties to deliver purpose-driven performance throughout the bag’s construction. Made from 100% pre-consumer recycled nylon, cutting energy use by 45%, reducing greenhouse gas emissions by over 30%, and using 20% less water.

- Reduction in manual labor through automation
- Reduction in quality deviation
- Reduction of fail points within the product
- Cost & material savings
- Streamlined production process (minimal secondary processes)
- Creates a unique seamless design aesthetic

Design Challenge

One of the greatest challenges of this project was mastering a highly specialized technology from the ground up. As someone new to 3D knitting, I had to completely rethink my approach to design, adapting my process to align with the unique constraints and possibilities of the production method. This required not only a deep technical learning curve but also a shift in mindset—designing for a medium where form, function, and fabrication are inherently intertwined. Pushing into uncharted territory to create a product that had never been made before meant constant experimentation, iteration, and problem-solving at every stage.

Project Duration

2021-2025

Operation Flow

The Luma is more than a bag—it’s a movement toward smarter, more responsible design. By fusing technology with sustainability, we’ve created a product that not only meets modern consumer demands but sets a new benchmark for the industry. It reflects my belief that through innovation, we can reduce waste while creating purpose driven products. This is the future of carry—seamless, sustainable, and revolutionary.

Research

This 3D knit backpack is the result of five years of dedicated research and development, beginning with early swatches and culminating in refined, production-ready samples. Over the course of this project, more than 20 unique knit designs were created and iterated upon. The most successful elements from each were synthesized into a cohesive design language. We developed approximately 10–12 fully functional prototypes, each exploring variations in knit structures, material compositions, and functional features. These prototypes were tested across diverse environments and with users from a wide range of lifestyles, providing critical feedback that informed the final product’s performance, comfort, and durability.

Inspiration

The lightbulb went off and the idea really took shape after a trip to China, where I witnessed the immense waste and labor intensity in traditional soft goods manufacturing. During this trip I had the overwhelming feeling that there had to be a better way of creating these products. I set out to find a better solution that would lessen the reliance on a globalized supply chain, promote local community manufacturing, and leave less of an impact on our planet. That experience pushed me to explore 3D knitting—a process that eliminates excess material, reduces labor, and enables precise, zero-waste production. This backpack redefines how soft goods are made, proving that sustainability, performance, and thoughtful design can go hand in hand.

Image Credits

Colin Heston

Patents

Patent No. US10959506B2

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