Get Better Trail in your inbox.

Subscribe here.
MENU

Thule Aion Travel Backpack 40L Review

Andrew Shults bio photo
By Andrew James Shults
Dec 23, 2025
When you buy through our links, we may receive a commission.
Our Take:
4.1/5
Certified

For a travel pack that lacks a hipbelt, the Thule Aion 40L provides a surprisingly comfortable carrying experience. Its padding and backpanel are both above average for this category, and its attractive canvas polyester build provides solid durability for lugging it around on your adventures. We could do without the bulk and some needlessly complicated design choices, but the Aion still lands firmly in our good graces.

Comfort & Support

Comfort & Support

3.5/5
Organization

Organization

3/5
Durability

Durability

4/5
Water Resistance

Water Resistance

3/5
Weight & Size

Weight & Size

3/5
Sustainability

Sustainability

4.1/5

Capacities

40L (28L)

Fabric(s)

600D waxed polyester canvas

Hipbelt

No

Laptop Sleeve

Yes (16 in.)

Exterior Pockets

3

Weight

3 lb. 3.2 oz.

Pros

Handles 20-pound loads with ease, even on hikes longer than a couple of miles.
Backpanel features mesh and a central channel to promote airflow.
Hidden pocket above the shoulder straps securely stashes important essentials.

Cons

Bulky design that sticks out far from your back.
Organizer in the top pocket may feel like overkill for minimalist-minded users.
Laptop compartment is a bit too heavily padded, and eats into the main compartment’s space.

For this season's top models, see our guide to the Best Travel Backpacks.

For a pack without a hipbelt, the Thule Aion 40L does a pretty darn good job of keeping your load comfortable when it’s on your back. The shoulder straps have enough padding that I didn’t notice any sharp pressure on my shoulders, and the backpanel has plenty of cushion instead of feeling like a flat slab of structured fabric. With the Aion aboard, I strolled through airport terminals and went on a 2.5-mile hike while carrying up to 25 pounds. Everything sat close enough to my back that it didn’t feel sloppy, and the sternum helped keep everything tight. (The strap is elastic, which I liked more than I expected—it keeps the yoke from splaying without feeling like it’s locking your chest in place.)


The Aion’s backpanel ventilation also did its job: the mesh and center airflow channel kept sweat buildup in check in a way that some foam-backed travel packs simply don’t. However, this is not some light, slim bag with a low profile. When it’s loaded up, the Aion sits pretty far from your back, and it can feel a bit like you’re toting around a boulder, bulk-wise. It’s not uncomfortable, but it’s not a subtle carry. Without a hipbelt, your shoulders are still doing most of the work (if you want a better carry overall, opt for a pack with a hipbelt, like The North Face Router or the Cotopaxi Allpa, or go whole hog with the Osprey Farpoint, which rocks a full suspension). Having said that, the Thule Aion Travel Backpack still feels better than the Yeti Crossroads and the Bellroy Lite, both of which also eschew hipbelts.

I liked some of the Aion’s storage options, while others felt overcomplicated. Its basic layout is fairly straightforward, and it’s built around a suitcase-style opening. Once you unzip the lid, you’ll see that one side has a huge zippered mesh pocket and the other side is the main packing area. There’s also a small mesh pocket near the top of the main compartment that works well for toiletries or loose items. I really enjoyed the thoughtful bonus of the included TPU packing bag, which is super helpful for separating stinky clothes or other dirty items from the rest of your stuff. Mine stayed tucked at the bottom until I needed it, and when I did, it was an easy way to separate my laundry.


The exterior of the Aion looks simple, but it has some tricks up its sleeve(s). For one, the hidden pocket above the shoulder straps is a home run. It’s secure, discreet, and easy to access when the pack is off your back. The water bottle pocket is also nice to have, and it fits most bottles I tried, including a Nalgene. (The catch is that it’s a bit shallow, so I’d be careful when bending over or moving fast through crowds.)


The parts I didn’t love about this travel pack are the Aion’s laptop compartment and dorsal pocket. The laptop area is padded and subdivided, which sounds great until you realize how much space it takes from the rest of the pack. I like protection, but this felt like it crossed the line into wasted volume, and the little zippered pocket inside that compartment wasn’t very satisfying to use. The dorsal pocket has a lot going on—lots of sleeves, lots of small, separated compartments—but it’s cramped, and the layout made it harder to actually see what I’d packed. It felt like organization for organization’s sake, rather than a clean system that makes travel simpler.

Build quality is one of the more reassuring parts of the Aion, although this isn’t a super-rugged pack. The 600-denier, waxed canvas polyester feels thick and sturdy without looking too crunchy or techy, and this pack definitely isn’t flimsy. All of the hardware, from zippers to handles to buckles, feels well constructed. Over a few days of use—travel days plus some time on the trail—the Aion handled normal abrasion without issues.


This pack isn’t a tank, though. There aren’t obvious reinforcements in high-wear zones, and while I didn’t feel like it needed them for typical travel, it’s not in the same durability tier as truly rugged travel backpacks like the Aer Travel Pack 3 or the Topo Designs Global. One other note: waxed canvas shows wear more than some synthetic fabrics. Some people will like that broken-in look, and others might not prefer how quickly it starts showing scuffs and creases.

The Thule Aion 40L’s waxed canvas material also features a durable water-repellent finish, which boosts its weather resistance. It still doesn’t reach the heights of TPU- and PU-coated models like the Patagonia Black Hole or the Allpa (not to mention the REI Co-op Ruckpack 30, which has a rain cover), but it’s much better than nothing. This bag will give your gear basic protection in drizzles, and can probably even handle a hefty splash from a puddle. I wouldn’t pick it for a trip where you expect to be spending a lot of time going from location to location outside in the rain, though.

Given its comfort and high degree of organization, the Aion’s 3-pound, 3-ounce weight doesn’t feel unreasonable. It’s not light, but it’s also not a pain in the neck (and back). The bigger story is this bag’s size and shape. This is a bulky pack that doesn’t compress down very small, and the straps don’t tuck away as they do on many other models that I’ve tested.


The Thule Aion Travel Backpack also sticks out farther from my back than I wanted, which makes it feel larger when you’re carrying it than some other packs with similar capacities. It works as a carry-on, but I wouldn’t plan on squeezing it under an airplane seat unless you’re fine donating most of your legroom.

Select icon to view details:

Icon
Icon
Icon
Icon
Icon
Icon
Icon
Icon
Icon
Icon

Longevity

Choosing durable outdoor gear and keeping it in use for longer is one of the best ways to reduce environmental impact. Our proprietary longevity rating assesses factors like overall build quality, materials, fabric denier, component durability, and real-world performance. A green check indicates that we expect the product to be long-lasting relative to its peers, a yellow check mark indicates average longevity, and a red X indicates a product that may have a limited lifespan.

The Aion comes in the 40-liter version that I tested, as well as a smaller, 28-liter version. I’m 5-foot-10 and weigh 185 pounds, and I thought that it fit me well. The harness sat comfortably on my shoulders, and the backpanel provided cushion and support despite the lack of a hipbelt. It hugged my back better than the Bellroy Lite and felt more natural than the Patagonia Black Hole.


Even compared to other travel backpacks in this size range, though, the Aion’s depth and stiffness make it feel like it takes up a lot of space behind you. If you don’t like bulky packs or worry about knocking into your fellow travelers, slimmer models might make more sense.

Yeti Crossroads 35L ($250): Sleekness Over Comfort
Unlike the Aion, the Crossroads (another travel pack without a hipbelt) struggles with heavy loads. Its shoulder straps have minimal padding, and its foam backpanel quickly leads to sweat buildup. Still, the Crossroads delivers a sleeker silhouette while giving up only five liters of capacity. It trades the Aion’s bulky laptop compartment for two slimmer sleeves and relocates the water bottle pocket inside. A zippered mesh divider keeps contents more secure than the Aion’s flimsy compression straps, and Crossroad’s top pocket favors a simple design without a sleeve-heavy admin panel (though it retains a key clip). And while the Aion is quite durable, the Crossroads goes a step further with a 700-denier nylon shell and a PU-coated base. If you value minimalist design and durability, it makes sense to spend the additional $40 for the Crossroads. But for all-day comfort, stick with the Aion. For more, read our Crossroads 35L Backpack review.


Aer Travel Pack 3 ($249): Better Organization, More Durable
The Travel Pack 3 shares a lot in common with the Aion. Both comfortably handle 25 pounds—the Travel Pack 3 does so with load lifters, while the Aion has a more comfortable elastic sternum strap. They’re both bulky, with a bulbous feel on your back. When it comes to organization, however, the two differ significantly. We found the Aion’s admin panel and laptop compartment awkwardly laid out and over-engineered, whereas the Travel Pack 3’s pared-down front pocket and laptop sleeve made keeping track of gear easier. That said, we appreciated the packable TPU-lined bag inside the Aion’s main compartment, which kept our tester’s dirty clothes separate. Still, its materials can’t match the Travel Pack 3’s high degree of durability—its 1680-denier Cordura nylon is almost three times as thick as the Aion's fabric. Taken together, we think all of that is worth the extra $39. For more, check out our review of the Travel Pack 3.

Thule Aion 40L ($210)
Thule Aion Travel Backpack 40L laptop sleeve
4.1/5

The Aion offers a decently comfortable carry, which says a lot for a pack that forgoes a hipbelt. We’re not huge fans of its bulky, sometimes overengineered design, but its tough, stylish exterior means you won’t have to worry about your stuff (or this pack) taking much damage.

Capacities
40L (28L)
Fabric(s)
600D waxed polyester canvas
Hipbelt
No
Laptop Sleeve
Yes (16 in.)
Exterior Pockets
3
Weight
3 lb. 3.2 oz.
Icon

Comfort & Support

3.5/5
Icon

Organization

3/5
Icon

Durability

4/5
Icon

Water Resistance

3/5
Icon

Weight & Size

3/5
Icon

Sustainability

4.1/5
Yeti Crossroads 35L ($250)
Pulling notebook out of Yeti Crossroads 35L Carry On Backpack front zip pocket
4.3/5

The Crossroads is a rugged, well-organized pack for travelers who aren’t afraid to bring their gear into rough environments. However, its build is geared more towards light loads, and you’ll want to wear a shirt that you don’t mind sweating in.

Capacities
35L (22, 27L)
Fabric(s)
700D nylon
Hipbelt
No
Laptop Sleeve
Yes (15 in.)
Exterior Pockets
3
Weight
3 lb. 11.2 oz.
Icon

Comfort & Support

3/5
Icon

Organization

4/5
Icon

Durability

4/5
Icon

Water Resistance

4/5
Icon

Weight & Size

3/5
Icon

Sustainability

2.8/5
Aer Travel Pack 3 ($249)
Aer Travel Pack 3 water bottle side pocket
4.5/5

The Travel Pack 3 looks fairly unassuming, but it’s as burly as they come. The mega-tough build should keep it in fighting shape for years, and it also boasts intuitive organization and a solid carry. It’s bulky, though, and misses out on some quality-of-life features.

Capacities
35L (28L)
Fabric(s)
1,680D Cordura nylon
Hipbelt
No (Sold Separately)
Laptop Sleeve
Yes (16 in.)
Exterior Pockets
5
Weight
4 lb. 1.9 oz.
Icon

Comfort & Support

3.5/5
Icon

Organization

4.5/5
Icon

Durability

5/5
Icon

Water Resistance

3.5/5
Icon

Weight & Size

2.5/5
Icon

Sustainability

1.5/5

Is the Thule Aion 40L for You?

Thule has a reputation for making quality luggage, and the Thule Aion 40L doesn’t do much to challenge that narrative. This pack’s durability, organization, and comfort should all be good enough for the vast majority of travelers, although finicky organizers and minimalists may find faults in its design. But if carrying comfort and a solid build matter more than a perfect pocket layout, and you want a pack with a dash of class, the Aion is an appealing option.