Lightweight Waterproof Blankets for a North American Outdoor Brand
A North American outdoor brand needed picnic and camp blankets that were waterproof, lightweight and packable. We engineered a 20D ripstop shell and delivered 8 colorways on schedule.
Challenge
Waterproof, Light and Packable
Casa Outdoor, a North American brand, wanted a picnic-and-camp blanket that packed down to the size of a paperback, weighed under 600 g, yet stayed genuinely waterproof on damp ground. They also needed fast-drying fabric and eight colorways to match their seasonal palette.
The timeline was tight: 75 days to bulk, including a new fabric development because their existing supplier could not hit the weight target.
Solution
20D Ripstop Shell with TPU Coating
We engineered a 20-denier ripstop nylon shell with a TPU coating — waterproof to a 5,000 mm hydrostatic head yet only 85 g/m². The fill was a recycled polyester wadding for cushioning and warmth without weight.
A bonded seam-taping process replaced stitching on all joints, eliminating needle holes as a leak path. We ran color lab-dips in parallel and delivered all eight SKUs in a single bulk run.
Result
Hit Target Weight and Launched on Schedule
The final blanket weighed 540 g and packed to 18 × 12 cm. All 8 colorways shipped on schedule for the spring launch. Casa Outdoor placed a repeat order for a fleece-lined version in the same season.