What a custom hard shell jacket is
A hard shell is the outermost layer in a layering system. It uses a waterproof breathable membrane laminated to a face fabric, and its seams are sealed with tape so that water cannot enter through the needle holes. That is what separates it from a softshell jacket, which trades full waterproofing for stretch and breathability. If you are still deciding between the two, our guide on hard shell vs softshell jackets compares them side by side.
For a brand, a custom hard shell is also the most demanding garment to develop: the fabric system, the pattern, the hood geometry, the zippers and the seam-sealing plan all have to work together. Mont Gear manages those decisions in one development process so the sample you approve is the garment you receive in bulk.
Hard shell construction options
| Construction | How it is built | Typical use | What to know |
|---|---|---|---|
| 2-layer (2L) | Face fabric + membrane, with a separate hanging liner (mesh or taffeta) | Lifestyle jackets, insulated shells, classic rain jackets | Liner adds comfort and some weight; membrane sits on the inside of the face fabric |
| 2.5-layer (2.5L) | Face fabric + membrane + printed or sprayed protective layer | Packable rain and trail shells | Lightest and most packable; the protective layer is less durable than a full backer |
| 3-layer (3L) | Face fabric + membrane + bonded backer, all laminated together | Alpine, ski, mountaineering and premium hiking shells | Best durability and next-to-skin feel; see our 3-layer shell jacket page |
Features we develop
- Helmet-compatible hoods with stiffened brims and two- or three-point adjustment
- Water-resistant front zippers with storm flaps and chin guards
- Pit-zip or mesh-lined ventilation
- Pocket systems: chest, hand, internal drop and harness-friendly layouts
- Articulated sleeves, underarm gussets and raised back hems
- Adjustable cuffs and hems; welded, silicone or heat-transfer logo details
- Packability: stuff pockets, light fabrics and reduced hardware
Construction details from one of our samples
Close-ups of a colour-block shell jacket from our development line: storm flap with hook-and-loop tabs, drawcord hood, zippered hand pocket and adjustable cuff.
Typical spec ranges
| Item | Typical range | Notes |
|---|---|---|
| Face fabric | 20D to 100D nylon or polyester, ripstop or plain | Mechanical stretch face is an option for movement |
| Laminate weight | Roughly 100 to 250 g/m² for most outdoor shells | Lighter for packable, heavier for alpine and ski |
| Waterproofness | Commonly 10,000 to 28,000 mm hydrostatic head | Method (for example ISO 811 or AATCC 127) is set in the tech pack |
| Breathability | Commonly 10,000 to 25,000 g/m²/24h | The test method must match the claim you publish |
| Seam tape | 13 to 20 mm, matched to the laminate | Different tape for 2L, 2.5L and 3L builds |
| DWR finish | Durable water repellent, including PFAS-free options | Confirm rules in your target markets |
Ranges are industry-typical and for orientation only. Actual values depend on the fabric selected and are confirmed in your quote and test plan.
How a hard shell program runs
- Brief and tech pack review. We check category, target market, construction and performance requirements. See tech pack development.
- Fabric and membrane matching. Buyer-nominated materials or recommended options, with availability and lead time confirmed.
- Pattern and first sample. Fit, hood geometry on a helmet, sleeve articulation and layer compatibility. See pattern engineering.
- Seam-sealing plan and testing. Tape map, bonding settings and the agreed tests. See seam-sealed construction.
- Pre-production sample. Final approval of fit, details, labels and test results.
- Bulk production and QC. Inline checks, seam-tape inspection and final inspection. See factory and quality control.
Matching products
Most hard shell programs are developed as a set. We build the matching hard shell pants and bibs from the same fabric system and colourways, and adapt the jacket for ski and snow, hiking and alpine or climbing use.
What to send for a quote
- Tech pack, sketch or a reference garment (photos and measurements are fine to start)
- Size range, sizing market and quantity per style and colour
- Fabric direction: hard shell, softshell or a named Polartec® platform, plus target price
- Required features: hood type, pockets, vents, zippers, insulation, reflective details
- Testing needs (for example hydrostatic head, breathability, seam strength, wash tests)
- Sample timeline and bulk delivery window
Trademark note: Third-party branded membrane and fabric names belong to their respective owners and are used here only as buyer search terminology. Material access, authorization, labeling rules and public performance claims are confirmed for every program.
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