MODULAR ALPINE INTERFACE: 3-IN-1 SYSTEM

THE CONCEPT: MECHANICAL APPRECIATION

In 2023, I expanded a standard school brief into a full interchange system to study the "Visible Logic" of late 20th-century technical gear. This project is a forensic study of the 1991 Columbia Gizzmo. My objective was to reverse-engineer an established 40-year-old system to understand how two disparate garments physically interface while maintaining a full range of motion.

It is important to note that I do not claim the foundational interchange logic as my own. I used the heritage of the Columbia system as a masterclass to learn the mechanics of high-component assembly. My contribution lies in the modernized slim block, the specific component geometry, and the digital development and manual execution of the 93-piece build.

SOURCE: COLUMBIA SPORTSWEAR COMPANY | CORPORATE ARCHIVE (PORTLAND, OR)

CATALOG REF: 1991 TECHNICAL OUTERWEAR | GIZZMO™ INTERCHANGE SYSTEM

BARRIER TECH: FIRST-GENERATION OMNI-TECH™ (2L MICROPOROUS PU COATED)

CONSTRUCTION ANALYSIS

01 / THE SHELL: COMPONENT DENSITY

Drafted from fit model measurements for a custom slim block, the shell updates the silhouette while retaining the functional foundation of the interchange system.

  • Textile Logic: I utilized a 100% Nylon with a Microporous PU Coating. Given the 2-Layer (2L) construction, I integrated a mesh hanging liner to protect the hydrophobic barrier and manage internal moisture.

  • Protection Systems: A high-overlap double-flap front protects two sets of YKK Vislon® zippers. Integrated chin guards and inner zip guards isolate the hardware from the wearer.

  • Offset Geometry: The primary shell zipper and the interchange zipper are offset. This placement is a deliberate decision to minimize bulk and bunching at the center front when the layers are joined.

  • Utility: Features fleece-lined on-seam pockets and an internal pocket for shell packability. Hem and cuffs are adjustable via elastic and hook-and-loop fasteners.

02 / THE LINER: THERMAL ASSEMBLY

The liner utilizes Primaloft® Gold insulation to provide high-clo warmth without the requirement of external quilting. The assembly includes two internal pockets for storage when worn as a standalone jacket.

03 / VOLUME AND TOLERANCE

To prevent internal bunching, I calculated a 5% volume differential. The shell is drafted with specific ease at the armhole and chest to house the loft of the liner.

  • Modular Anchors: Connections at the neck and cuffs use precise turn-of-cloth calculations. This ensures the rib-knit cuffs sit flush inside the shell sleeve, creating a windproof seal without pressure points.

  • Assembly Logic: The Center Front (CF) assembly required a specific 14-step nesting order to ensure the inner zip-guard and interchange zippers functioned without hardware interference.

DESIGN LANGUAGE AND COLOR

TECHNICAL STANDARDS

STITCHING SNL at 9 to 11 SPI

SEAM ALLOWANCES 3/8" (Main) / 1/2" (Pocket Bags) / 1" (Liner Headers)

HARDWAREYKK Vislon® Zippers / Hook and Loop Fasteners

TEXTILES100% Nylon (2L Coated) / Primaloft® Gold Insulation

THE SPECS

  • Pattern Development: Jacket block & 83 final pattern pieces (60 Shell / 23 Liner) developed in Optitex 2D.

  • Documentation: Technical Package.

  • System: Independent 2L technical shell and standalone insulated liner.

  • Execution: Full sample assembly including industrial hardware integration.

The pairing of Grey-Blue and Yellow-Beige provides visual harmony when the jacket is worn open, balancing the metallic tone of the shell with the organic warmth of the liner. The shell utilizes rectangular design lines to establish a structured look, contrasting with the body-contouring of the liner. Contrasting zipper colors provide a clear visual hierarchy and ease of use.