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Behind the Design: Wind Challenger Stretch Down Jacket

Join us at L.L.Bean headquarters for an insider’s look at how we create our next-generation product for next-level comfort.

4 Min. Watch | Buying Guides

A Tradition of Problem Solving

When you speak with Product Development Manager Melissa M., one thing is immediately clear: the process of designing L.L.Bean outerwear starts and ends with the customer. We listen to their needs, then find the most innovative solutions to address them. The Wind Challenger Stretch Down Jacket is a product of this philosophy, packed with problem-solving features that help you beat wind and chill whether you’re taking a winter stroll or hitting the slopes.

The Need: A Better Way to Windproof

As warm and versatile as a traditional down puffer is, it will always be limited by the simple realities of its construction. Normally, the baffles that hold insulation in place are sewn, creating tiny stitch holes that allow wind to permeate the shell – and on occasion let down feathers escape. This same stitching prevents the inclusion of any stretch in the material – a benefit that adds more comfort and movement during long stretches of activity.

“This garment solves for all the problems we’ve seen in previous down construction, plus has the added benefit of stretch. That feels to me like the holy grail of a down-insulated jacket.”

Melissa M., Product Development Manager

“This garment solves for all the problems we’ve seen in previous down construction, plus has the added benefit of stretch. That feels to me like the holy grail of a down-insulated jacket.”

Melissa M., Product Development Manager

The Solve: Stretch the Definition of What a Down Jacket Can Do

So, Melissa and her team went to work, sourcing a complex double-weave technique that minimizes stitching to achieve a number of benefits that elude most down jackets. Less stitching mean less puncturing, which creates a stronger shell that does a better job keeping down feathers in and windy weather out. The unique woven construction also allowed Melissa’s team to give customers something we’ve never been able to offer before in a down jacket: stretch.

“Now you get this beautiful stretch that gives you an insulated piece that’s more wind resistant, more thermally efficient, and also gives you great comfort.”

Melissa M., Product Development Manager

“Now you get this beautiful stretch that gives you an insulated piece that’s more wind resistant, more thermally efficient, and also gives you great comfort.”

Melissa M., Product Development Manager

It’s All in the Details

It took months of close collaboration between talented product designers, developers, and our in-house testing lab to bring this jacket from sketch to store – and their expertise can be found in every detail. From ski-friendly features to thoughtful additions for all your outdoor endeavors, this piece delivers innovation for real life.

650-Fill DownTek™ Down

Light, lofty water-repellent down that continues to insulate even when wet.

Outdoor Tough

Water-resistant and windproof, with reinforced abrasion resistance on hood, shoulders, and bottom of sleeves.

Built to Be Active

With features like pit zips to dump heat during more intense activity.

Ready for the Slopes

Helmet-compatible hood, hem cinches to keep snow out, and scan-and-go ski pass pocket on sleeve.

Ready to try out the Wind Challenger Stretch Down Jacket for yourself? You can get it here – or shop other innovative Outerwear pieces for everything you do outside.

For more product videos, tips, tricks, and outdoor inspiration, visit Explore L.L.Bean.

Melissa M smiles for the camera

About Melissa M., Product Development Manager, Outerwear

Melissa has worked for L.L.Bean for 18 years, beginning her career on the sales floor in the Camping department. It was there that she honed her talent for listening to what customers want and need. Since transitioning to Product Development, she has driven the creation of outerwear for everyone from the littlest toddlers all the way up to the most hardcore outdoor enthusiasts. For Melissa, the most fulfilling part of being a product developer is creating products that prolong a person’s enjoyment of the outdoors. “It’s great when someone thinks it looks good,” she says, “but it’s most rewarding when someone gets really jazzed up about the functionality.”

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