I love senior design projects. I still remember how fun mine was. A carbon fiber pack frame would be a great idea. I would ditch the cot idea, either keep it a single use item or maybe use it for tent supports or a chair. Here are some variables that would sway people to purchase one.

1. cost. Aluminum is pretty cheap. It is also easy and cheap to manufacture. Plastic is really easy to mold as well.
2. Weight. If you can beat the weight and durability of an internal frame suspension system, then it wouldn't matter how much it would cost.
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