Advances in synthetic materials have lead to incredibly innovative gear with remarkably price tags.

Look at any 2010 trail riding catalog and one thing becomes apparent: backcountry gear has gone synthetic. But rather than stick your head in the sand, why not learn how synthetics keep your caboose more comfortable, your sack lunch colder, and your pocketbook fatter?

• High-Denier Fabrics

“Denier” refers to the weight (read: strength) of woven fabrics like nylon and polyester. Fifteen denier is so fine it appears transparent (it’s used in lingerie), while 1800 denier is ballistic quality (it’s used in luggage). The new line of Outfitters Supply saddlebags, for example, is made of 1680 denier nylon.

“This material is remarkably resistant to rips and scrapes,” says Russ Barnett, packer and founder of Outfitters Supply, a company based in Columbia Falls, Montana.

Verdict: This is the easiest synthetic product to like. It’s become universally accepted in the outdoor apparel industry and it’s about time the horse market got on board. As for the look: it’s great for day trail riders, but not so much for historical re-enactors.

• Waterproof Zipper

In the 1950s, the National Aeronautics and Space Administration (best known by the acronym NASA) designed an air pressure-proof zipper for use in space. More than 50 years later, the design is now waterproof thanks to plastic teeth that are coated with polyurethane, and rubberized seams and joints. According to Barnett, the zippers are “remarkably resistant to rain, sleet and snow.”

“They glide smoothly across a rubberized seal to make each saddlebag is  completely waterproof,” he says.

Verdict: It stops water, true, but the zipping action feels stiff and can jam under heavy use. The zipper could use more work, but improvements shouldn’t take another 50 years.

• Injection Molded Polymer

Injection molding is a manufacturing process that shoots polymer, a plastic, into a form where it solidifies in the shape of anything from a bottle cap to a car part to a packsaddle tree.

“Traditionally, the best pack trees were made from old-growth cottonwood,” Barnett says. “But it’s expensive and hard to come by now. We experimented with injection molded polymer and discovered that it matches a traditional wooden tree in strength, weight, and feel.”

Verdict:  Polymer trees provide a consistent level of quality at an affordable price—they’re the Levi 501 jeans of packsaddles. The only problem is you can’t shape the bars of a plastic tree with a rasp, as you can a wooden tree, to fit a specific mule’s back. On the plus side, polymer trees will outlive you (and your great-grandchildren).

• Closed Cell Foam

Picture an NFL running back being tackled by the biggest defender in the league. What keeps him alive is the closed cell foam in his shoulder pads and helmet. This synthetic material is composed of tiny plastic bubbles fused together in fabric form. It’s kind of like bubble wrap for people. 

“We use closed cell foam in our saddlebags and riffle scabbards,” Barnett says. “It protects their contents against abrasion, impact, and it works as an insulator.”

Verdict:  The foam lining of a saddlebag is a great, yet undetectable, innovation. It is hidden inside the bag’s polyester lining, where it performs its job without being so synthetically in-your-face.

• Ralide

Pull back the leather on most factory-made saddles and you’ll find Ralide. Like polymer, it’s a plastic-based injection molded product.

“Ralide can take a heavy impact, and it doesn’t weaken or crack in extreme cold,” Barnett says.

These qualities make it ideal for heavy-use gear like pack panniers, stirrups, and saddle trees.

Verdict: Durable and light, Ralide deserves its reputation. My only question: is the bright orange color necessary?