Luggage Materials Comparison

A deep dive into luggage construction materials. Understand what you're buying and which materials best suit your travel needs.

Hardside Materials

Polycarbonate

The Premium Choice

Polycarbonate is the gold standard for hardside luggage. It's lightweight, impact-resistant, and flexible enough to absorb pressure without cracking.

Pros:

  • Excellent impact resistance - flexes under pressure, returns to shape
  • Lightweight compared to other hard materials
  • Highly durable for frequent travel
  • Scratch-resistant with textured finishes

Cons:

  • More expensive than ABS
  • Can show scratches on glossy finishes
  • Quality varies by manufacturer

Brands known for polycarbonate: Samsonite, Rimowa, Delsey, LEVEL8

ABS (Acrylonitrile Butadiene Styrene)

ABS is a common plastic used in budget to mid-range luggage. It's rigid and affordable but less durable than polycarbonate.

Pros:

  • Very affordable
  • Rigid structure provides basic protection
  • Widely available in many styles and colors

Cons:

  • More brittle - can crack on impact
  • Heavier than polycarbonate
  • Less durable long-term
  • Prone to permanent dents

Common in: Budget brands, Amazon basics, starter luggage

ABS + Polycarbonate Blend

Many mid-range bags combine ABS and polycarbonate to balance cost and durability. The ratio varies - more polycarbonate means better performance.

What to look for: Brands listing "polycarbonate blend" or "ABS+PC" should specify the ratio. 80/20 polycarbonate/ABS is much better than 20/80.

Aluminum

Pure aluminum luggage (like Rimowa Original) offers maximum protection but at a premium price and weight penalty.

Pros:

  • Maximum protection for fragile contents
  • Iconic look that develops character over time
  • Extremely durable - lasts decades
  • TSA-friendly flush locks

Cons:

  • Very expensive ($1000+)
  • Heaviest option
  • Dents easily (some see this as character)
  • Requires more maintenance

Softside Materials

Ballistic Nylon

The Durability Champion

Originally developed for military flak jackets, ballistic nylon is the toughest softside fabric available. It's virtually tear-proof and extremely abrasion-resistant.

Pros:

  • Exceptional durability and tear resistance
  • Abrasion resistant - handles rough baggage handling
  • Water resistant (not waterproof)
  • Professional appearance

Cons:

  • Heavier than other fabrics
  • More expensive
  • Limited color options (mostly black)
  • Stiffer feel

Brands known for ballistic nylon: TUMI, Briggs & Riley, Hartmann

Cordura

Cordura is a brand name for a family of durable fabrics. It's lighter than ballistic nylon but still highly durable.

Pros:

  • Lighter than ballistic nylon
  • Excellent abrasion resistance
  • More color options available
  • Good balance of weight and durability

Cons:

  • Less tear-resistant than ballistic nylon
  • May show wear faster in high-friction areas

Polyester

Standard polyester is the most common softside material, found in budget to mid-range luggage.

Pros:

  • Affordable
  • Lightweight
  • Many color and pattern options
  • Easy to clean

Cons:

  • Less durable than nylon
  • Can tear or abrade
  • May look worn faster
  • Less water resistant

Quality varies: Denier count matters - 600D is minimum; 1000D+ is more durable

Hardside vs. Softside: The Verdict

Factor Hardside Softside
Protection Better for fragile items Good for clothing
Water Resistance Excellent (sealed shell) Moderate (fabric treatment)
Weight Varies (PC light, aluminum heavy) Generally lighter
Flexibility Fixed shape Can squeeze into tight spaces
Expansion Limited (2-3" typical) Often more expandable
External Pockets None or minimal Multiple pockets common
Appearance Modern, sleek Classic, professional
Maintenance Easy - wipe clean May require fabric care

Choosing Based on Travel Type

Choose Hardside If You:

  • Carry fragile items (electronics, glass bottles, souvenirs)
  • Travel in rainy or wet conditions
  • Want easy cleaning after trips
  • Prefer a modern aesthetic
  • Check bags frequently (more protection from handlers)

Choose Softside If You:

  • Need to squeeze bags into tight spaces (car trunks, overhead bins)
  • Want external pockets for quick access
  • Prioritize light weight
  • Travel for business (professional look, document pockets)
  • Mainly pack clothing and soft goods

Understanding Quality Indicators

Zippers

YKK zippers are the industry gold standard. Look for this brand on quality luggage. Coil zippers (like on most clothing) are lighter but less secure than tooth zippers. Self-repairing zippers (used by Briggs & Riley) can handle light zip separation.

Handles

Quality telescoping handles use aluminum or steel tubes with multiple height settings. Budget bags often use plastic tubes that can break. Test handle stability - it shouldn't wobble or have play.

Wheels

Quality wheels use sealed bearings for smooth rolling. Cheap wheels have exposed bearings that collect debris. Replaceable wheels extend bag life - check if your brand offers replacement parts.

Stitching

Look for double or triple stitching at stress points (handle attachments, corners, zipper ends). Loose threads or inconsistent stitch lines indicate lower quality. Reinforced stress points add durability.