Black Ember FORGE 40L Expandable Travel Backpack

BLACK EMBER FORGE 40L Expandable Travel Backpack

The latest addition to the FORGE Collection. This FORGE is carry-on ready and built to travel. It starts at 30 liters and expands to 40. Like the original FORGE, it’s designed to be carried three ways: Backpack, Brief, and Shoulder Bag. 

Your essentials are right at hand in the fast-access panel, and two additional exterior pockets function as both storage and pass-through to the interior. The top pocket is especially made for our BOARDING KIT, with all your flight essentials. The Black Ember Packing Cubes complete the entire kit. The Black Ember Forge 40L Expandable Backpack is the flagship carry option from Black Ember!

The interior features three separate sections. The organization panel gives you access to the boarding kit on one side and additional storage on the other. The main compartment features ample space for clothing and footwear. When you need more space: pull the expansion zipper and expand to 40 liters. If you max out the storage space, compress the FORGE with our magnetic compression straps. 

Your laptop and tablet are isolated in one compartment: protected by layers of quilted EVA Foam and rip-stop nylon. Laser-cut, locking zipper pulls secure your gear. The Black Ember Forge 40L Expandable Backpack features our custom anodized and laser-etched aluminum hardware. 

Ergonomic 3D shoulder straps with two densities of EVA foam provide both cushion and support. Dial in your fit with Load-Lifters and a magnetic sternum strap. A contoured back-panel with an air-channel to keep you cool and dry. Our butterfly back-panel keeps your straps hidden, until you need them. An optional hip-belt can also be added.

Black Ember Forge 40L features our latest textile: EmberTex™. With EmberTex™, we have now removed all PFAS (forever chemicals) from our supply chain. EmberTex™ is a twisted nylon 6 with an abrasion resistant matte finish, a lustrous texture and a smooth hand feel. The 1200x600 Denier gives it more structure for ease of packing and access. Combined with YKK® Aquaguard zippers, the it is durable and weatherproof. Laser cut and bonded Hypalon panels embedded in its shell add structure where it's needed.

The Dopp Kit is a great addition to the kit! Is 40 Liters too much? Check out our Forge 30

All Black Ember products are made using our BOND-STITCH™ high-precision construction. All textile components are Laser-Cut for precise assembly. This construction yields a weatherproof, durable pack with a blacked-out, minimal aesthetic.

 FAQ

• What is the Black Ember FORGE 40L?
• A 3-way carry pack (backpack/brief/shoulder) that compresses for daily use and expands to 40L for 1–3 day travel. Professional aesthetic, weather-resistant build, and organized access.
• What are the key features?
• It is a 3-way carry; perimeter expansion from 30L to 40L; dedicated suspended laptop/tablet compartment; clamshell main access; fast-access top pocket; pass-through exterior pockets; butterfly back panel to stow straps; luggage pass-through; Fidlock sternum strap; optional shoulder strap, hip belt, and Maglock compression straps.
• What are the exact dimensions and capacity
• Compressed: 20 x 12 x 8 in (51 x 31 x 20 cm). Expanded: 20 x 12 x 10 in (51 x 31 x 25 cm). Capacity: 30–40L. Weight: approx. 5 lb (2.25 kg).
• What laptops are compatible with it.
• Dedicated, suspended laptop sleeve fits up to most 16-inch laptops, with quick access. Separate tablet sleeve.
• What Materials and hardware is it made with?
• EmberTex PFAS-free shell; YKK Aquaguard zippers; laser-cut Hypalon details; anodized aluminum hardware; 210D ripstop lining; Fidlock magnetic sternum strap and key ring.
• What is it like in terms of carry and comfort?
• Ergonomic, dual-density shoulder straps; contoured back panel with air channel; load stability from structured build; strap-stow “butterfly” panel for brief/shoulder carry. Very comfortable!
• What is the organization and access like?
• The Black Ember Forge 40L has three zones: admin/organization, main clamshell, and dedicated laptop/tablet compartment. Quick-access top pocket. Exterior pass-through pockets into main body.
• Is it water and weather resistant?
• Yes! It has a weather-resistant shell and Aquaguard zippers designed to protect tech in light rain and daily urban conditions.
• What fits in it (daily and travel)?
• Daily: 16″ laptop, charger kit, tech pouch, water, lunch, light jacket, documents. Travel (expanded): 1–3 days of clothing, footwear, Dopp kit, with room for work essentials.
• Does it comply with Airline carry-on guidance?
• Height/width align with typical carry-on rules. Depth expands from 8″ to 10″; compress for stricter carriers.
• Are there optional add-ons?
• Yes. Shoulder strap, hip belt, Maglock compression straps, external bottle holder (if used).
• What are the trade-offs to consider?
• Structured durability adds some weight. Expansion zippers add bulk and work best with deliberate operation.
• Who is it best for?
• Professionals and commuters who want one bag for office, gym add-ons, and weekend travel without sacrificing a clean, refined look. Business travel too! People with refined taste ;-)

KEY FEATURES

• 3D ERGONOMIC SHOULDER STRAPS WITH A REMOVABLE STERNUM STRAP
• SEPARATED AND SUSPENDED BUILT-IN TABLET & LAPTOP SLEEVE
• FIDLOCK® MAGNETIC KEY RING
• HYPALON THEFT-DETERRENT LOCKING ZIPPER PULLS
• LUGGAGE ATTACHMENT STRAP
• EXPANSION COMPARTMENT
• BUTTERFLY BACK PANEL
• BOARDING KIT COMPATIBLE TOP POCKET
• OPTIONAL MAGNETIC COMPRESSION STRAPS WITH T6 ALUMINUM HARDWARE SOLD SEPARATELY

DIMENSIONS:

• Dimensional inches compressed: 20 x 12 x 8
• Dimensional inches expanded: 20 x 12 x 10
• Dimensional centimeters compressed: 51 x 31 x 20
• Dimensional centimeters expanded: 51 x 31 x 25
• Liters: 40 
• 12 inch tablet compatible
• 16 inch laptop compatible
• Base weight : 5 lbs, 2.25 kg

LAPTOP DIMENSIONS

• Dimensional inches: 16.5 x 12 x 1.25
• Dimensional centimeters: 42 x 30 x 3.18

CRITICAL MATERIALS & HARDWARE

• EMBERTEX™ PFAS FREE : 1220X600 Nylon 6
• 210 DENIER MATTE-SILVER RIPSTOP NYLON LINING 
• DURABLE ELASTIC POWER MESH
• FIDLOCK® MAGNETIC HARDWARE
• FIDLOCK® MAGNETIC KEY RING
• YKK® AQUAGUARD ZIPPERS
• T6, AIRCRAFT-GRADE ANODIZED ALUMINUM + LASER ETCHED HARDWARE
• LASER-CUT + LASER-ETCHED HYPALON
• HYPALON THEFT DETERRENT LOCKING ZIPPER PULLS