Osprey Exos 48 Pack Review

Osprey Exos 48 Field-test and Review

I’ve been field-testing the Osprey Exos 48 for months, across trails ranging from the jagged terrain of Tasmania’s Du Cane Range to the coastal views over Freycinet Peninsula. It’s an overnight and multi-day hiking pack, and after all those diverse conditions I have a solid read on where it earns its reputation and where it doesn’t. For context, my previous experience with Osprey packs includes the Aether AG™ 70, which I reviewed back in 2017, and that pack left a lasting impression, so I was curious to see how the Exos 48 would measure up.

First Impressions: A Lightweight Companion

The Exos 48 stood out immediately for its balance of weight and functionality. It weighs just 1.29 kg for the S/M size, which makes it a strong option if you prioritise a lightweight pack without giving up essential features, and the 48 litres of space suits hikers who pack efficiently but still need room for their gear. If you need more capacity, there’s a 58-litre version (load range 11-14 kg), and if you’d rather go smaller, there’s a 38-litre model too (load range 9-11 kg).

When I first put it on, it felt streamlined, with a snug, ergonomic fit. Knowing your pack isn’t bulky, while still being capable of carrying everything you need for an extended hike, matters more than it sounds like it should. The slim profile, helped by the ExoForm harness and Ultralight AirSpeed® suspension, hugs the body well and gives good balance when you’re carrying a moderate load.

What impressed me most was how the AirSpeed® suspension kept me cool, with real airflow between the pack and my back. I’ve tested plenty of packs that claim this, but once they’re fully loaded the mesh usually compresses and the pack ends up sitting flush against your back anyway. That wasn’t the case here. My back stayed noticeably drier, and the airflow made a genuine difference. It’s also made with 100% recycled materials, which is a welcome bonus if you’re trying to reduce your footprint.

One thing worth flagging is a design change from earlier Osprey models that affects anyone who uses a pack cover. The lower section of the suspension is now attached directly to the pack, which makes it harder to secure a cover properly, you used to be able to thread the cover’s strap underneath the suspension for a snug fit, and that’s no longer an option. In practice, you’ll either leave the cover slightly unsecured or use a larger cover with an extended strap to compensate. I run a large pack cover myself, so it’s never been an issue for me, but it’s worth knowing if your cover is a snug fit.

Comfort and Fit: Customisable Adjustments

The pack comes in two torso lengths, so the first step is measuring your torso to get the right size. From there, you can fine-tune the suspension length for a more customised fit. Once it’s adjusted, it stays put, so it’s really a set-and-forget feature once you’ve dialled it in.

The heaviest load I’ve carried in this pack was around 16kg, mostly on trips where I needed to carry extra water because I couldn’t rely on the sources along the way. The recommended weight range is 11-14kg, but I found it stayed comfortable up to about 16kg. Past that, you’d be better off looking at a larger 60-70 litre pack for the sake of weight distribution and storage.

ExoForm Harness

The ExoForm harness is genuinely comfortable, largely because of its seamless, layered mesh design. It’s breathable and soft, which reduces discomfort on long treks, and the mesh also adds cushioning, something I noticed on the multi-day hikes I did in Tasmania.

The two injection-moulded adjustment ladders make torso length adjustment easy and let the pack fit a range of body types. I appreciated how simple it was to tweak the torso length on the move, just slide it up or down the LightWire frame, lock it into place, and you’re done.

ExoForm Hipbelt

The hipbelt deserves a mention too. It’s adjustable, comfortable, and stays put even after hours of hiking. The ErgoPull cross-body buckle makes it easy to tighten or loosen for that balance between a snug fit and enough room to move, and over my 4-day hikes the hipbelt stayed comfortably in place with no rubbing or pressure points.

The padding is relatively lightweight, but it’s enough to avoid hip bruising, and it distributes the pack’s weight across the hips well.

Storage and Organisation: Thoughtful Features

The Exos 48 has a variety of thoughtful storage solutions, making it easy to organise your gear and get to it on the go.

Top Lid and Attachment Points

The removable floating lid, or brain, is a standout. I use it for gear I need regular access to, my torch, power bank, sunscreen, sunglasses, and it’s genuinely useful being able to grab something quickly on the trail. The lid also has dual upper side compression straps with quick-release buckles that help keep the load stable and tight. If you’d rather go lidless, Osprey includes a FlapJacket cover. I don’t use it much because I prefer having the lid on for multi-day trips, but it’s there for when you want to travel lighter.

Hydration and Quick Access

If you use a hydration bladder, there’s an internal sleeve with a hose port at the centre back. I mostly use separate water bottles myself, but the bladder system worked fine during testing. Worth noting that a full bladder does make the pack feel a bit less accessible, particularly getting into the lower compartment, though when it’s packed properly the weight distributes evenly.

The front stretch mesh pocket is one of my favourite features, perfect for stashing quick-access gear like a rain jacket or camp sandals. I’ve also used it for wet gear like my fly and rain cover. It’s one of those pockets you end up using constantly.

Side Pockets and Compression Straps

The side-entry pocket design on the Osprey packs is fantastic. Being able to grab and stow a bottle without taking your pack off makes a huge difference in keeping up regular hydration. Julie and I usually hike together, so it’s pretty easy to share bottles or grab the other person’s from side packs when needed. I’ve used a few other brands with top-of-pocket access, but Osprey really seems to have nailed it with the opening along the leading edge. I can simply reach back and grab my own bottle. When I first started wearing Osprey packs, I was still inserting my bottles from the top, but the side entry makes life so much easier. A huge selling point for me. The dual-access stretch mesh side pockets are spacious enough to fit my 1.5L water bottles, but they’re also versatile enough to hold tent poles or hiking poles without issue. This flexibility, being able to easily access gear from both the top or side, even while wearing the pack, adds a level of convenience that I appreciate on the trail.

However, one downside I encountered was that the stretch mesh can snag on vegetation. On a recent multi-day hike through the Du Cane Range in Tasmania, I wasn’t lucky enough to avoid the typical Tassie bush, and a few small holes tore in the mesh, which I’ll have to figure out how to repair. Still, it’s a small trade-off for the convenience and capacity these pockets offer. I’ve worn other packs and was quite disappointed in their side pockets, which were so low-cut that I had to clip my bottles in place with a carabiner for fear they would fall out, or so deep there was no way I could get the bottle out without removing my pack.

The dual strippable side compression straps are another great feature, allowing me to secure extra gear or stabilise my load when I don’t need full compression. Given the volume of the pack and the compact gear I carry, I don’t often find the need to use the compression straps to shrink the load within the pack. Instead, I’ve used them to secure my water bottles, hiking poles, and tent poles by attaching them to the webbing with a lightweight carabiner.

Durability and Performance: Built for Adventure

The Exos 48 is built for rugged conditions, but as with any lightweight pack, there are things worth keeping in mind. The stretch mesh pockets, while convenient, are more susceptible to damage than sturdier materials, which is exactly what caught up with me on the Du Cane Range. The rest of the construction is solid though, bluesign® approved recycled high-tenacity nylon ripstop with a PFC/PFAS-free DWR coating for durability and water resistance. The base uses the same 100D nylon ripstop as the main fabric, while the accents are reinforced with 400D high-tenacity nylon for extra toughness in high-wear areas. After everything I’ve put this pack through so far, it’s holding up well.

In terms of functionality, the Exos 48 holds its own on tough terrain. I’ve used it across sandy beaches, rocky scrambles, and wet, muddy trails, and it’s held up well throughout. The LightWire frame provides strength without unnecessary weight, and the suspension carries a full load comfortably. The compact profile also helps with balance on off-trail sections.

Special Features: Extras That Matter

Ice Axe Loops and Trekking Pole Attachment

The Exos 48 comes with dual ice axe loops for alpine hikers. I haven’t tested these in alpine winter conditions yet, but they seem solid based on what I’ve tried at home. The Stow-on-the-Go trekking pole attachment is a genuinely useful feature too, letting you stash poles quickly while wearing the pack. I’ve used it occasionally when I needed both hands free for scrambling, though I’ll admit I often default to stashing poles in the side pockets out of habit.

Hipbelt Pockets

The dual zippered hipbelt pockets are a practical addition for keeping small essentials like snacks, a whistle, or a PLB within easy reach. They aren’t the largest pockets I’ve used, and I do wish they were bigger, especially since I have other packs without them and miss the convenience when I don’t have it. I typically use them for snacks, a compass, and my whistle, and sometimes my PLB when it’s not attached to the harness. Given everything else the Exos 48 offers for storage, these pockets do their job well enough.

Osprey Exos 48 Backpack – Pros & Cons

What I love:

• Lightweight & Comfortable: Weighs only 1.29 kg, making it ideal for multi-day hikes.
• Breathable Suspension: AirSpeed® suspension prevents excessive back sweat.
• Customisable Fit: Adjustable torso length and ergonomic ExoForm harness ensure a snug fit.
• Supportive Hipbelt: Stays secure without rubbing or causing discomfort.
• Thoughtful Storage: Includes a removable floating lid, stretch mesh front pocket, and hydration bladder sleeve.
• Side Pockets with Dual Access: Easy reach for water bottles and trekking poles.
• Durable Materials: Made from high-tenacity recycled nylon with reinforced high-wear areas.
• Eco-Friendly: Uses bluesign® approved materials and PFC/PFAS-free water resistance.
• Versatile Compression Straps: Can be used for securing extra gear.
• Trekking Pole & Ice Axe Loops: Convenient for alpine hikers and technical routes.
• FlapJacket Cover: Provides an alternative to the removable top lid.

Things to be mindful of:

• Limited Load Capacity: Recommended weight range of 11-14 kg; although I am confident it can handle a lot more.
• Mesh Side Pockets Are Fragile: Can snag and tear on rough vegetation.
• Suspension Design Affects Pack Cover Fit: Makes it harder to secure rain covers snugly.
• Hipbelt Pockets Could Be Larger: Limited space for bulkier items.
• Water Bladder Storage Can Reduce Accessibility: A full bladder slightly limits access to lower compartments.

Tech Specs

• Cubic Inches: S/M 2929, L/XL 3112
• Litres: S/M 48, L/XL 51
• Weight: S/M 1.29 kg (2.84 lbs), L/XL 1.33 kg (2.94 lbs)
• Dimensions:
  S/M: 75h x 36w x 30d cm (30h x 14w x 12d in.)
  L/XL: 79h x 40w x 32d cm (31h x 16w x 13d in.)
• Load Range: 11-14 kg (25-30 lb)
• Add-On Options: 3L Reservoir, Raincover (M)

Overall, the Exos 48 is a well-designed, functional pack that gets the balance of lightness, comfort, and durability right. It’s held up as a dependable companion across my hikes, and the thoughtful features, the adjustable harness, the attachment points, the stretch mesh pockets, have made it a go-to, even with the trade-offs: the mesh that snags on vegetation, the pack cover that no longer sits as snugly as it used to, and hipbelt pockets I’d still like to see a bit bigger. For those looking for a women’s-specific fit, Osprey also offers the Eja, which my wife has and loves, though fit and comfort matter more than the label, so it’s worth trying both to see what actually works for you. Check it out on the Osprey website here.