Choosing the right suitcase material is more important than you might think. It has a major impact on the durability, weight, and overall protection of your luggage. In this guide, you’ll find out which materials are worth considering – and which ones to avoid.
About the author
My name is Sebastian, and I’ve been specialising in luggage since 2017. I test products, give honest advice, and help travellers find the best suitcases.
Hard-shell suitcase materials
Wide range – but big differences in quality
CURV
CURV is one of the most advanced suitcase materials on the market, known for its exceptional lightness and high impact resistance. Made from thin, woven polypropylene fibres, it’s fused under heat and pressure into an ultra-strong yet flexible shell – making CURV suitcases among the lightest in the world.
Even compared to polycarbonate, CURV is often more flexible and more durable, absorbing shocks with ease while resisting cracks and breakage. Another key advantage is its performance in extreme temperatures: unlike many plastics, CURV remains tough even in freezing conditions.
At present, only Samsonite uses this high-tech material in its luggage range. While it comes at a higher price due to the complex manufacturing process, a CURV suitcase is an excellent long-term investment for travellers who want minimum weight and maximum durability.
Samsonite Lite Shock – made of CURV
Thanks to its CURV construction, the Samsonite Lite Shock is the lightest suitcase in the world. The shell is also extremely durable and almost indestructible. Overall, the Lite Shock impressed across the board and secured 2nd place in the suitcase test.
Polycarbonate
Polycarbonate is a top-quality suitcase material, valued for its high impact resistance and durability – ideal for frequent travellers. One of its biggest strengths is its flexibility, which helps absorb shocks without cracking, even in rough handling.
Because it’s so tough, polycarbonate can be used in thinner shells, making suitcases lighter without compromising strength. It also performs well in both hot and cold climates, maintaining its shape and resilience even in extreme temperatures.
The only downside is the price: polycarbonate is more expensive than other plastics. But if you’re looking for long-lasting quality and lightweight strength, it’s well worth the investment.
Samsonite Neopulse – made of polycarbonate
For me, the Samsonite Neopulse is the best travel suitcase overall. It offers an excellent all-round concept and comes with high-quality features. The premium polycarbonate shell makes it both very lightweight and extremely shatter-resistant.
Polypropylene
Polypropylene is one of the lightest materials used in suitcase production, making it a great choice for travellers who want to keep their luggage weight down. Despite its lightness, it offers good durability and strong resistance to breakage. Its elasticity helps absorb impacts effectively, although it’s not as flexible as polycarbonate.
A downside of polypropylene is its lower temperature resistance. In very cold conditions, it can become more brittle and prone to cracking. It’s also a softer material, meaning the surface is more susceptible to scratches.
Still, polypropylene offers excellent value for money. It’s an ideal option for budget-conscious travellers looking for a lightweight case without sacrificing reliability.
American Tourister Soundbox – made of polypropylene
This popular suitcase from American Tourister was the best value winner in the suitcase test. Made from high-quality polypropylene, it’s tough and absorbs impacts well. For a hard-shell case of this quality, the price is hard to beat.
ABS
ABS (Acrylonitrile Butadiene Styrene) is a hard plastic known for its good surface hardness and impact resistance. As a suitcase material, it offers a solid balance between price and performance, making it a popular choice in the budget segment.
However, ABS is less flexible than materials like polycarbonate or polypropylene, which means it absorbs shocks less effectively. This can increase the risk of damage, especially during air travel. ABS suitcases also tend to be heavier, as they need thicker shells to achieve similar strength and durability.
Despite these drawbacks, ABS remains a cost-effective option for travellers looking for basic durability at an affordable price.
Hauptstadtkoffer Mitte – made of ABS plastic
The Hauptstadtkoffer Mitte stood out in the suitcase test for its generous capacity and stylish design. While the ABS plastic makes the shell very rigid, it also lacks flexibility. The material’s weight is noticeable – this model is heavier than most polycarbonate or polypropylene suitcases.
Aluminium
Aluminium is a premium material used in hard-shell suitcases, known for its exceptional strength and long-lasting durability. It offers excellent protection, forming a rigid barrier against pressure and impact.
However, aluminium suitcases are noticeably heavier than plastic alternatives, making them less practical for air travel with strict weight limits. Their reduced flexibility also means they can dent or crack more easily under force.
That said, the sleek metal surface is highly scratch-resistant and keeps its appearance for years. For travellers who prioritise security, style and longevity, aluminium remains a solid – if heavier and pricier – choice.
Soft-shell suitcase materials
Nylon vs. polyester
Nylon
Nylon is an exceptionally durable and long-lasting material often used in high-quality soft-shell suitcases. It’s tear-resistant, abrasion-proof and flexible, making it ideal for frequent travellers. Another advantage: nylon is naturally more water-repellent than polyester, helping to protect your belongings better from moisture – such as rain or wet floors.
Nylon suitcases often feel smoother and more premium, and they tend to retain their shape even with frequent use. They are typically more expensive than polyester models but offer a longer lifespan and better protection in everyday travel situations.
Samsonite Airea – made of nylon
The Samsonite Airea is made from premium nylon and is one of the lightest suitcases in the world. It also impresses with its exceptionally spacious interior and practical extras like front and side pockets. The use of nylon gives it a sleek, elegant look and contributes to its long-lasting quality.
Polyester
Polyester is the most commonly used material for soft-shell suitcases. It’s lightweight, flexible, and affordable. Compared to nylon, the fabric typically has a slightly coarser weave, which affects both the texture and the appearance. While polyester suitcases are generally less water-repellent and not quite as durable as nylon models, they offer excellent value for money. For occasional travellers, polyester is a practical and budget-friendly choice.
Samsonite Litebeam – made of polyester
The Samsonite Litebeam is one of the lightest soft-shell suitcases on the market. It offers generous packing space, smart features and comfortable handling. The value for money is outstanding – it’s rare to find a suitcase with this combination of weight and features at such an attractive price.
Conclusion: the best suitcase material
No clear winner – but I do have a personal favourite
The most exciting and innovative material, in my opinion, is CURV. It allows for extremely lightweight suitcases with a strong yet flexible shell. However, it’s only used in a few premium models – and the price is fairly high.
That’s why I consider polycarbonate the best all-round suitcase material. It offers the ideal mix of impact resistance, durability, and temperature stability – all while remaining relatively light. It’s more affordable than CURV, but still noticeably higher in quality than most plastics.
Polypropylene strikes a great balance between performance and price. It’s lightweight and strong, but less temperature-resistant than polycarbonate and more prone to surface scratches.
For me, ABS falls short. While it’s cheap, ABS suitcases are often heavier and much less flexible, which increases the risk of cracks. That makes it the least reliable option.
When it comes to soft-shell suitcases, you’ll usually be choosing between nylon and polyester. Both materials are lightweight and flexible, but they differ in quality: nylon is more durable, longer-lasting and naturally more water-repellent, but it also tends to be more expensive. Polyester, on the other hand, offers great value for money and is ideal for occasional travellers or those on a budget.
FAQ
Your questions about suitcase materials
Polycarbonate or polypropylene – which is better?
Polycarbonate is more robust and offers better impact resistance than polypropylene. On the other hand, polypropylene is significantly lighter and more affordable. If you travel frequently and prioritise durability, polycarbonate is the better option. For occasional travellers who value low weight, polypropylene is a great choice.
ABS or polycarbonate – which material is the better option?
Polycarbonate outperforms ABS in almost every respect: it’s more flexible, more impact-resistant and longer-lasting. ABS suitcases tend to be cheaper, but they’re heavier and more prone to cracking on impact.
ABS or polypropylene – which is more recommended?
Polypropylene is generally the better choice when it comes to weight and durability. ABS is cheaper, but heavier and less shock-resistant. Polypropylene offers a good balance of weight, flexibility and price.
Which suitcase material is the most durable?
Aluminium is considered the most durable suitcase material. It provides excellent protection against pressure and point loads. However, it’s less impact-resistant, can dent on heavy knocks and is significantly heavier. A close second is polycarbonate, which offers excellent protection thanks to its flexibility and high impact resistance – all at a much lower weight.
Which suitcase material lasts the longest?
Curv is one of the most durable materials available. It’s extremely impact-resistant, retains its shape well, and performs reliably even in extreme temperatures. Polycarbonate is another excellent choice, especially for frequent travellers. It also offers long-lasting performance, usually at a lower price than Curv, though it’s slightly heavier.
Vote now: which suitcase material do you prefer?
Cast your vote and see the live results straight away. Feel free to share your thoughts with the community in the comments!
