Ultralight Windshell

Full zip, breathable, wind and weather resistent, packable shell


UL Windshell 2022 Redesign!
  • Redesigned pattern from ground up for better fit and to layer perfectly with Alpha Raglan Hoodie
  • Full-zip weather resistent shell with zippered hand pockets
  • Deep seam raglan sleeves that avoid shoulder strap discomfort and maximize range of motion
  • Redesigned three-piece fitted hood with brim stiffener that won't blow off in wind
  • Highly packable and truly UL at only 3 ounces for size medium in 1.0oz HyperD fabric including hand pockets!
Sewing Skill Level - Advanced Beginner
While a beginner can make this project, familiarity with sewing terms and construction techniques is expected. For best results, a serger is recommended. A zig zag or overlock stitch will work but results may vary based on individual skill. This is a great beginner garment pattern with technical ultralight woven fabrics. Make a prototype and have fun!
Body Measurements and Fit Guide
Detailed instructions on getting a great fit are included. Sizing covers wide range of chest sizes measuring 32 inches up to 52 inches corresponding to RTW sizing XXS to XXL. Custom fit adjustments are illustrated within the instructions. In the photos, I'm (6'0" tall, 170 lbs, 39" chest) wearing a size medium. See pattern preview photo in gallery above for finished garment sizes.
Body Measurement (inches) 32 (XXS) 34 36 40 44 48 52 (XXL)
Chest (Upper Bust) 30-32 33-34 35-37 38-40 41-44 45-48 49-52
Natural Waist 24-26 26-27 28-30 32-34 36-38 40-42 44-46
Low Waist 30-32 33-34 35-37 38-41 42-45 46-48 49-52
Sleeve 30 31 32 33 34 35 36


RipstopByTheRoll is my preferred shop for ultralight breathable fabrics with DWR that are perfect for the UL Windshell. For the most breathable windshell, look for uncalendered fabric such as 1.0oz HyperD. Higher denier, higher weight per yard fabrics will be noticably more durable and easier to sew. For example 1.6oz HyperD vs 1.0oz HyperD. A few excellent recommendations:

  • HyperD is uncalendered for maximum breathability, won't feel clammy, and has good sewability.
  • MEMBRANE fabrics are incredibly lightweight and buttery smooth to touch, but not beginner-friendly.
  • 1.1oz Ripstop Nylon or Ripstop Polyester (OutdoorINK) are budget and beginner-friendly.
  • MONOLITE mesh is the lightest and most durable pocket liner option I've found.

Fabric Panel Recommended Length (Width)
Main Body 1.6oz HyperD has best balance of weight, durability, sewability, and cost.
1.0oz HyperD is noticably softer and more breathable but feels less durable and has lower sewability.
2 yd (58")
Pocket Lining Self fabric or 1.0oz MONOLITE mesh 12 inches (24")
Neck Binding 5/8" or 3/4" ribbon or 1/2" single fold bias tape 1 yd estimated
Cuff Elastic 3/8" or 1/4" flat elastic 8-10 inches
Main Zipper YKK#5 Vislon molded tooth, Seperating 30 inches estimated
Pocket Zippers YKK#3 non-seperating coil or reversible for packable pocket. Two 7 inches minimum
Hood Cinch Cord Optional 3/32" Shock Cord 30 inches
Cinch Hardware Optional Mini Cord Lock, plastic stopper bead one each

Digital Sewing Pattern

  • Complete step-by-step sewing instructions with photos
  • Cut layout, pattern sizing, and custom fit adjustment instructions
  • Non-gendered sizes from XXS-XXL for getting the perfect fit
  • Multiple PDF paper sizes for printing convenience
    • Print at home on 8.5x11 inch Letter or A4 sized paper
    • Print at office on 11x17 inch tabloid or A3 sized paper
    • Large format on two 36x48 inch sized sheets (North America)
    • Large format on three A0 sized sheets (UK/EU)
  • Seam allowances included for all pattern panels and sizes

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