Vollebak

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Next week we're launching the strongest, lightest and stretchiest shell we've ever built

Woven with two of the strongest materials on Earth

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July 27, 2026 12:57pm EDT

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How we built a shell from two of the strongest materials on Earth.

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Carbon Fibre Dyneema Shell | vollebak.com

Every high-performance shell is built around a trade-off. You can have something light. Or stretchy. Or tough. If you're lucky, two at once. But pushing all three at the same time is the point where materials science gets complicated and most people give up.

We didn't. Instead of hunting for a single miracle material, we borrowed an idea from aerospace engineers and the people who design the world's fastest cars: composite thinking.

Rather than ask one fibre to do everything, we built the Carbon Fibre + Dyneema® Shell from two radically different high-performance fibres, woven together into something you don't normally find in clothing.

Dyneema® is an ultra-high molecular weight polyethylene and the single strongest fibre we know of. Weight for weight it's up to 15 times stronger than steel. Which is why it's used to make bulletproof vests, armour for tanks and the ropes that hold deep-water oil rigs in place in violent, icy seas.

We wove thousands of white strands of Dyneema® horizontally through our nylon base material.

Crossing it vertically is a black carbon fibre, normally used to reinforce components in missiles, jet engines and the world's fastest cars. Definitely not jackets.

Each strand is almost pure carbon, its atoms locked into crystals that line up along its length, the same basic structure as graphene, which is what makes it so strong for its size.

Then we had to make the whole thing stretch. Carbon fibre is usually baked with resin into something completely solid. It’s the glossy black weave you see on a supercar or a race bike. Build a jacket from that and it wouldn't bend, let alone move with you.

So we did something different. We engineered both fibres into tiny spirals and wrapped them around an elastane core, so they behave like high-tensile springs, expanding and compressing as the shell stretches.

Then we added a serious amount of elastane on top, more than a quarter of the finished shell.

The result is a shell that stretches in every direction at once, while standing up to the same abrasion tests as our toughest 100 Year gear.

Because the grid is woven from white Dyneema and black carbon fibre, up close the shell has a fine micro check, and from a distance it reads as a clean technical grey. The grid even rises slightly out of the surface, giving it a texture you can feel.

Everything else gets out of the way so the material can do the work. That includes invisible zipped pockets, raglan sleeves, hidden snap cuffs and an internal hem drawcord.

The Carbon Fibre + Dyneema® Shell weighs 500 grams. It's also water repellent, breathable and lined with air-jet-textured Cordura.

It's the strongest, lightest and stretchiest shell we've ever built.

NICK AND STEVE TIDBALL - FOUNDERS

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Carbon Fibre Dyneema Shell | vollebak.comollebak.com

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