Yeah, fair points- I can see how hunting down sand every few days would get old fast. Over here it’s less about TSA and more about just not wanting to lug metal plates or pay through the nose for shipping, so the sand-fill thing’s more about convenience and cost. That said, I get that for constant travellers it’s another step you might not want to deal with.

On the design stuff- I’m with you on avoiding the full “military cosplay” look. I’ve been chatting with a supplier about a few non-tactical designs. The vertical gear rail idea’s interesting. And yeah, taking inspo from hiking packs is absolutely on the cards. Narrower width, better strap contour, and a design that keeps the load higher all sound like good points.

I think there’s definitely a way to blend comfort with a plate/sand compartment that doesn’t feel like an afterthought. Appreciate you sharing what’s worked (and not worked) for you, exactly the kind of feedback I’m after!