When shopping for carry-on luggage, the sheer variety of materials and construction types can overwhelm even experienced travelers. Polycarbonate, ABS, aluminum, nylon, polyester, ballistic fabric—each material offers distinct characteristics that suit different travel styles and priorities. This guide breaks down everything you need to know to choose the right luggage material for your needs.
Hard Shell vs Soft Sided: The Fundamental Choice
The first decision when choosing luggage material is whether to go with a hard shell or soft-sided bag. Each category has devoted advocates, and the best choice depends on how you travel and what you prioritize.
Hard shell luggage offers superior protection for fragile contents. The rigid exterior absorbs impacts and resists crushing, making hard shells ideal for travelers carrying electronics, camera equipment, or breakable souvenirs. Hard shells also resist moisture better, keeping contents dry during rain or wet tarmac handling.
Soft-sided luggage provides flexibility and often weighs less than hard shell equivalents. Fabric bags expand to accommodate souvenirs, compress into tight overhead bin spaces, and often include exterior pockets for quick access to frequently needed items. Many travelers find soft bags more versatile for varied travel scenarios.
Quick Comparison
Choose Hard Shell If: You carry fragile items, travel in wet climates, prefer easier cleaning, or want maximum contents protection.
Choose Soft Sided If: You value flexibility, want lighter weight, need exterior pockets, or frequently squeeze bags into tight spaces.
Hard Shell Materials Explained
Polycarbonate
Polycarbonate represents the premium standard in hard shell luggage materials. This thermoplastic polymer offers an excellent balance of strength, flexibility, and weight. Quality polycarbonate shells flex on impact rather than cracking, absorbing shock while springing back to shape.
Originally developed for bulletproof glass and astronaut helmets, polycarbonate brings serious durability credentials to luggage. The material resists scratches better than some alternatives and handles temperature extremes well—important for bags sitting on hot tarmacs or cold cargo holds.
Pure polycarbonate luggage tends toward the premium price range. Brands like Rimowa, Samsonite's high-end lines, and Australian brand July use quality polycarbonate in their flagship models. The investment typically pays off in longer lifespan and better performance under stress.
ABS (Acrylonitrile Butadiene Styrene)
ABS plastic offers hard shell protection at lower price points than polycarbonate. This rigid plastic provides decent impact resistance and comes in virtually unlimited colors and finishes. Many budget-friendly hard shell options use ABS construction.
The tradeoff for lower cost is reduced flexibility and durability. ABS is more prone to cracking under severe impact than polycarbonate. The material also scratches more visibly and may show wear more quickly. For occasional travelers or those prioritizing budget, ABS provides adequate protection, but frequent flyers often find polycarbonate worth the premium.
Polycarbonate-ABS Blends
Many mid-range bags use blended materials combining polycarbonate's flexibility with ABS's cost-effectiveness. These hybrids offer middle-ground performance and pricing. When evaluating blends, the proportion matters—a shell that's 90% polycarbonate performs closer to pure polycarbonate than a 50/50 blend.
Polypropylene
Polypropylene represents an increasingly popular alternative to polycarbonate. This material offers excellent impact resistance, often outperforming polycarbonate in drop tests. Polypropylene shells are typically highly scratch-resistant and maintain appearance well over time.
Samsonite's Lite-Shock line uses Curv, a proprietary polypropylene-based material that's remarkably lightweight while providing exceptional strength. American Tourister and other brands also offer polypropylene options at various price points.
Hard Shell Materials Ranked
- Best Durability: Polypropylene (Curv), Aluminum
- Best Value: Polycarbonate-ABS blends
- Best Flexibility: Pure Polycarbonate
- Budget Option: ABS
Aluminum
Aluminum hard shells occupy the luxury end of the luggage market. Brands like Rimowa's Original line and similar premium options use anodized aluminum for unmatched durability and distinctive aesthetics. Aluminum luggage develops character over time—dents and marks tell stories of travels past.
The downsides of aluminum include significantly higher weight and cost. An aluminum carry-on might weigh 4-5 kilograms empty versus 2-3 kilograms for polycarbonate equivalents. With 7kg weight limits on many Australian carriers, that difference substantially reduces packing capacity.
Soft Sided Materials Explained
Ballistic Nylon
Ballistic nylon represents the toughest fabric option for soft luggage. Originally developed for military flak jackets, this dense weave resists tears, abrasions, and punctures exceptionally well. Premium luggage brands like Tumi feature ballistic nylon in their signature collections.
The tight weave also provides water resistance without additional treatments. Ballistic nylon luggage handles years of rough handling while maintaining appearance and function. The material's weight per unit of protection often proves lighter than hard shell alternatives.
Cordura Nylon
Cordura is a fabric family rather than a single material, with various weights and constructions available. High-denier Cordura (500D, 1000D, or higher) offers excellent durability for luggage applications. Many outdoor brands and luggage manufacturers use Cordura for its proven performance.
Cordura fabrics typically receive durable water repellent (DWR) treatments enhancing moisture resistance. The material cleans easily and resists staining. Lower-denier Cordura options provide lighter weight while maintaining reasonable durability for less demanding use.
Polyester
Polyester fabrics offer budget-friendly soft-sided options. The material resists wrinkles and moisture reasonably well while costing less than nylon alternatives. Many entry-level soft bags use polyester construction.
Durability varies significantly with fabric weight and weave quality. Heavier denier polyester (600D or higher) provides adequate performance for light travel use. Cheaper, lighter polyester may wear through more quickly, particularly at stress points like corners and handles.
Matching Material to Travel Style
- Business Travel: Polycarbonate hard shell or ballistic nylon
- Budget Travel: Polyester soft-sided or ABS hard shell
- Adventure Travel: Cordura or ballistic nylon
- Frequent Flying: Quality polycarbonate or polypropylene
- Luxury Travel: Aluminum or premium polycarbonate
Beyond the Shell: Other Factors
While shell material matters significantly, other construction elements affect overall luggage quality. Zippers should be robust and operate smoothly—YKK zippers are an industry standard worth seeking out. Handles need reinforced attachment points to prevent pulling away under load. Wheels and wheel housings should feel solid and spin freely.
Interior construction matters too. Quality linings resist tears and stains. Well-designed pockets and dividers add organization value. Reinforced corners protect the most vulnerable points on any bag.
Choosing luggage material ultimately involves balancing priorities: durability versus weight, protection versus flexibility, premium performance versus budget constraints. Understanding what each material offers helps you make an informed decision aligned with your travel needs and style.