When it comes to travel backpacks, few options balance form, function, and comfort as well as the Gregory Border 40. This versatile pack has won over frequent flyers, weekend adventurers, and digital nomads alike. But before you hit the checkout button, there are some essential facts, features, and considerations to keep in mind. In this guide, we’ll walk you through 10 important things you need to know before buying the Gregory Border 40—so you can decide if it’s the right fit for your lifestyle.
1. It’s Designed for Urban and Air Travel – Not Backcountry Trekking
One of the first things to understand is what the Gregory Border 40 is—and isn’t. While it looks rugged, this pack is designed with urban travel, commuting, and air travel in mind. It’s not built for long treks in the wilderness or alpine adventures.
Its sleek clamshell design, padded laptop sleeve, and TSA-ready features make it ideal for city-to-city travel, quick flights, or business trips. If you’re looking for a hiking backpack with an internal frame and hydration system compatibility, you might want to consider Gregory’s trail-specific packs instead.
2. It Meets Most Carry-On Requirements
The “40” in Gregory Border 40 refers to 40 liters of capacity, which sits right on the edge of carry-on size for most airlines. With dimensions of approximately 21 x 14 x 9 inches, it meets the cabin baggage rules for airlines like:
Delta
United
Lufthansa
Emirates
British Airways
However, budget airlines like Ryanair or Wizz Air may have stricter limits. Always check your airline’s policy, especially if you plan to avoid checked luggage fees.
3. The TSA-Compliant Laptop Compartment Saves Time at Airports
One of the standout features of the Border 40 is the TSA-compliant laptop compartment. The clamshell-style bag opens flat, allowing airport security to scan your electronics without removing them from the bag.
The dedicated laptop sleeve is padded and fits up to a 17” laptop, while the tablet sleeve offers extra convenience for digital nomads or business travelers. This design saves time and hassle—especially if you’re rushing to catch a flight.
4. It’s Built for Comfort – Even When Fully Loaded
With a 40-liter capacity, you might be tempted to pack everything you own—but thankfully, Gregory has designed the Border 40 with comfort in mind:
Padded shoulder straps and sternum strap
Contoured back panel with airflow channel
Load lifters to stabilize heavy contents
While it doesn’t include a hip belt (a minor con for heavier loads), it remains comfortable for most users carrying up to 20 lbs (9 kg). The ergonomics strike a solid balance between portability and structure.
5. The Organization System Is a Traveler’s Dream
Packing and staying organized is where the Gregory Border 40 truly shines. The interior layout includes:
A large clamshell-opening main compartment
Separate zippered mesh compartments for clothing, cables, or toiletries
A dedicated laptop and electronics compartment
Quick-access top and front pockets for passports, chargers, or snacks
This internal division means no more rummaging for socks in the middle of the airport. It’s perfect for people who love staying tidy while on the move.
6. It’s Not Ideal for Long-Term Backpackers
If you’re setting off on a multi-month backpacking trip through Southeast Asia or South America, you might find the Gregory Border 40 too small or insufficiently rugged.
While perfect for weekend trips, work travel, or short holidays, its minimalist harness and lack of frame support limit it for extended travel where you’re carrying gear for weeks at a time.
For longer adventures, consider the Gregory Zulu or Osprey Farpoint 55, which offer better load support and modular features.
7. Durability Is a Strong Suit
The Gregory Border 40 is constructed from 210D and 420D high-density nylon, making it resistant to tears and abrasions. The zippers are YKK—known for their reliability—and the seams are reinforced.
It can handle overhead bin shoving, cobblestone streets, and rainy platforms. However, it’s not waterproof, so you might want to pack a rain cover or dry bags for wet weather.
8. It’s Versatile Enough for Daily Use
Not only is the Gregory Border 40 great for travel, but it’s also functional for daily or gym use. The laptop compartment and easy-access organization make it suitable for:
Commuters
Students
Freelancers working in cafés
Gym-goers needing clothes and shoes storage
This multi-purpose appeal adds extra value—especially if you’re looking to reduce how many bags you own.
9. It Comes in Two Sizes for a Better Fit
Gregory understands that one size doesn’t fit all. That’s why the Border 40 is available in:
S/M (Small/Medium)
M/L (Medium/Large)
This ensures a better fit for various torso lengths and shoulder widths. When choosing your size, consider trying it on in-store or measuring your torso length to avoid strain during travel.
10. It Offers Great Value for the Price
The Gregory Border 40 typically retails between \$130–\$170 USD, depending on the color and retailer. While not the cheapest pack on the market, its:
Thoughtful design
High-end materials
Brand reputation
Comfort and carry-on functionality
…make it an excellent value-for-money investment. If you travel even a few times a year, it pays for itself quickly compared to checked luggage fees or cheaper packs that wear out.
Conclusion: Should You Buy the Gregory Border 40?
If you’re a frequent flyer, minimalist traveler, or someone looking for a reliable carry-on bag, the Gregory Border 40 delivers impressive performance, style, and utility. Its TSA-friendly laptop access, smart organization, and rugged build make it ideal for modern travel.
That said, it’s not for everyone. If you’re an outdoor backpacker or need gear for long-term travel, you might want a larger, more specialized pack. But for most travelers, the Border 40 hits the sweet spot between functionality and convenience.
Whether you’re hopping from airport to Airbnb, commuting to a co-working space, or heading off on a weekend escape—this pack is ready for the ride.
FAQs About the Gregory Border 40
1. Is the Gregory Border 40 waterproof?
No, the Gregory Border 40 is water-resistant but not fully waterproof. It can handle light rain, but for heavy weather, use a rain cover or pack waterproof gear inside.
2. Does the Gregory Border 40 fit under the airplane seat?
Typically, it does not fit under the seat but is designed to fit in most overhead compartments. It’s larger than a personal item but acceptable as a carry-on for many airlines.
3. Can the Gregory Border 40 be used for hiking?
While durable, the Gregory Border 40 is not designed for hiking or outdoor adventures. It lacks features like hydration compatibility, hip belt support, and ventilation that hiking packs offer.
4. Is there a women-specific version of the Border 40?
Currently, Gregory does not offer a women-specific fit for the Border 40. However, the two sizing options (S/M and M/L) accommodate a variety of body types.
5. How does the Gregory Border 40 compare to the Osprey Farpoint 40?
Both are excellent travel backpacks. The Osprey Farpoint 40 has a more hiking-oriented suspension system and is slightly larger. The Gregory Border 40 wins in urban usability, laptop access, and sleek design.
