Luggage Materials Explained: From Polycarbonate to Aluminium

The material your suitcase is made from significantly impacts its durability, weight, protection capability, and price. With manufacturers using terms like polycarbonate, ABS, Curv, and Roxkin, it can be overwhelming to understand what you're actually buying. This comprehensive guide breaks down every major luggage material, helping you choose the right construction for your travel needs.

Hardshell Materials

Hardshell suitcases have surged in popularity over the past decade, offering superior protection for contents and a sleek, modern aesthetic. However, not all hardshell materials are created equal.

Polycarbonate: The Industry Standard

Polycarbonate is the most common material in quality hardshell luggage. This thermoplastic offers an excellent balance of strength, flexibility, and weight, making it the go-to choice for manufacturers from Samsonite to AWAY.

How it works: Polycarbonate's molecular structure allows it to flex under impact rather than crack. When your bag drops from an overhead bin or gets tossed by baggage handlers, polycarbonate absorbs and distributes the force across its surface. After impact, it returns to its original shape—a property called "impact memory."

ABS (Acrylonitrile Butadiene Styrene)

ABS is the budget-friendly alternative to polycarbonate. You'll find it in most entry-level hardshell luggage, often blended with polycarbonate to reduce costs while maintaining some performance characteristics.

Pure ABS is more rigid than polycarbonate and less able to flex under impact. This makes it more prone to cracking when subjected to the rough handling common in airports. However, for light travellers or those seeking an affordable starter suitcase, ABS can be adequate.

ABS-Polycarbonate Blends: Many manufacturers use blended materials, combining ABS with varying percentages of polycarbonate. A bag marketed as "polycarbonate blend" or "ABS/PC" typically contains more ABS than pure polycarbonate. Look for products that specify "100% pure polycarbonate" if material quality is a priority.

Polypropylene: The Durable Alternative

Polypropylene (PP) has gained popularity as a tough, affordable alternative to polycarbonate. Brands like American Tourister and Samsonite use polypropylene in many of their best-selling lines, including the popular Bon Air and Nuon series.

Unlike polycarbonate, polypropylene doesn't flex as much—it's stiffer and harder. This rigidity provides excellent protection against crushing but makes it slightly heavier. The material is also more resistant to scratching, making it ideal for travellers who don't want to baby their luggage.

Best for: Frequent flyers who prioritise durability over minimal weight, families with children, and travellers who check bags regularly.

Curv and Roxkin: Premium Composite Materials

Samsonite's proprietary Curv and Roxkin materials represent the cutting edge of luggage construction. These composite materials deliver exceptional strength-to-weight ratios that surpass traditional plastics.

Curv: Made from multiple layers of self-reinforced polypropylene, Curv was originally developed for military and industrial applications. In luggage, it creates shells that are remarkably thin yet incredibly strong. A Curv suitcase can weigh 30-40% less than an equivalent polycarbonate bag while offering better impact protection.

Roxkin: Samsonite's newest material uses a honeycomb structure to distribute impact forces across the entire shell. This allows for even thinner walls and lighter weight while maintaining exceptional durability. Currently found in premium Samsonite lines like the Proxis series.

Aluminium: The Luxury Choice

Aluminium luggage occupies the premium end of the market, epitomised by brands like RIMOWA and high-end Samsonite collections. These cases offer a distinctive aesthetic and exceptional durability, but they come with significant trade-offs.

Advantages: Aluminium shells provide rigid protection that plastic cannot match. They don't flex, so they maintain precise dimensions throughout their lifespan. Many travellers appreciate the prestigious appearance and the satisfying weight that signals quality. Over time, aluminium develops a unique patina of dents and scratches that some consider characterful rather than damaged.

Disadvantages: Aluminium is heavy—significantly heavier than any plastic alternative. A large aluminium suitcase might weigh 5-7kg empty, consuming a substantial portion of airline weight allowances. Aluminium also dents permanently; while it won't crack, every impact leaves a visible mark. Finally, aluminium cases are expensive, often costing $1,000+ for quality construction.

Best for: Travellers who prioritise aesthetics and prestige, those who don't mind the extra weight, and professionals who want their luggage to make an impression.

Softshell Materials

Softshell luggage remains popular for its flexibility, lighter weight, and external pockets that provide convenient access to frequently needed items.

Ballistic Nylon

Ballistic nylon was originally developed during World War II for military flak jackets. In luggage, this tightly woven synthetic fabric offers exceptional tear and abrasion resistance. High-denier ballistic nylon (1680D or higher) is virtually indestructible under normal travel conditions.

The material excels in flexibility—it can compress into tight spaces and doesn't crack or shatter. However, it offers less protection for fragile contents than hardshell alternatives and can absorb moisture if not properly treated.

Polyester

Polyester is the most common fabric in budget softshell luggage. It's lightweight, affordable, and available in countless colours and patterns. However, polyester is less durable than nylon and more prone to tearing and abrasion over time.

Look for higher denier counts (600D+) and reinforced stress points if choosing polyester luggage. Many budget manufacturers use 300D-400D polyester, which may wear through after extended use.

Cordura

Cordura is a branded fabric known for exceptional durability. Like ballistic nylon, it offers excellent resistance to tears, scuffs, and abrasion. Cordura is often used in premium soft luggage and backpacks designed for rugged travel conditions.

Understanding Denier

When shopping for softshell luggage, you'll encounter denier ratings (e.g., 420D, 840D, 1680D). Denier measures the thickness of individual fibres—higher numbers indicate thicker, more durable fabric.

• 300-400D: Budget fabrics, suitable for light use
• 420-600D: Standard quality, adequate for regular travel
• 840-1000D: Durable fabrics for frequent use
• 1680D+: Heavy-duty construction for demanding conditions

Matching Material to Travel Style

Your ideal luggage material depends on how and where you travel:

Frequent Flyers

Prioritise lightweight materials to maximise packing capacity. Curv, Roxkin, or quality polycarbonate offer the best strength-to-weight ratios. Avoid aluminium unless weight isn't a concern.

Adventure Travellers

Choose durable materials that handle rough conditions. Polypropylene hardshells or high-denier ballistic nylon softshells withstand cobblestones, dirt roads, and unconventional transport.

Business Travellers

Consider aesthetics alongside performance. Aluminium makes a statement, while matte-finish polycarbonate offers professional appearance with practical benefits.

Family Travellers

Prioritise durability and scratch resistance. Polypropylene handles the inevitable bumps and scrapes of family travel without showing damage.

Material Care Tips

Extend your luggage's lifespan with material-appropriate care:

• Polycarbonate: Clean with mild soap and water. Apply car wax to reduce future scratching on glossy finishes.
• Polypropylene: Wipe down with damp cloth. More forgiving of rough treatment than polycarbonate.
• Aluminium: Clean with aluminium-specific products. Accept dents as character—attempting removal often causes more damage.
• Nylon/Polyester: Spot clean with fabric cleaner. Allow to dry completely before storage to prevent mildew.

Understanding luggage materials empowers you to make informed purchasing decisions. Whether you prioritise weight savings, durability, or aesthetics, there's a material perfectly suited to your travel needs.