EP 251 – Ultralight Innovation & The Future of Gear – with Dan Durston

In this episode, I sit down with Dan Durston, founder and lead designer of Durston Gear, to dive deep into the world of ultralight shelters, backcountry design, and the future of small gear companies taking on the giants. We talk about Dan’s journey from long-distance thru-hikes like the Pacific Crest Trail and Great Divide Trail, to daydreaming gear ideas in the wilderness, to accidentally founding one of the most respected ultralight gear brands today. This conversation goes beyond shelters—it’s about innovation, passion-driven design, and how democratized manufacturing has opened the door for boutique companies to challenge industry leaders. If you’re into hunting, backpacking, or just geeking out on gear design, this one’s for you. ⏱️ Chapters 00:00 – Introduction & guest background 02:00 – Discovering ultralight backpacking 05:00 – Pacific Crest Trail planning, logistics & lessons learned 08:00 – Gear philosophy: weight efficiency vs. pure ultralight 12:00 – “Death of the Giants” & rise of boutique gear brands 16:00 – Daydreaming gear ideas on long hikes 20:00 – The birth of Durston shelters 25:00 – Fly-first pitch design & real-world use 28:00 – Business journey: partnerships, contracts & independence 32:00 – Why SilPoly changed the shelter game 36:00 – Material battles: SilNylon vs. SilPoly 40:00 – The evolution of Dyneema and shelter construction 45:00 – Ultra fabrics, durability, and real-world tradeoffs 50:00 – Lessons from building a grassroots gear company 55:00 – The future of ultralight innovation Durston Gear https://www.instagram.com/durstongear/ https://durstongear.com/ Jay Nichol jay@mindfulhunter.com https://www.mindful-reviews.com/ https://www.mindfulhunter.com/ Forged In The Backcountry https://forgedinthebackcountry.com/ Merch https://www.mindfulhunter.com/shop Newsletter https://www.mindfulhunter.com/contact IG https://www.instagram.com/mindful_hunter/ Podcast https://www.mindfulhunter.com/podcast Free Backcountry Nutrition Guide https://www.mindfulhunter.com/tools