Choosing the right suitcase is not just about style or size—it’s also about durability. Whether you’re a frequent flyer or an occasional traveler, a suitcase that can withstand impact, drops, and rough handling is essential for protecting your belongings. One of the key factors in a suitcase’s durability is its material. In this article, we’ll explore the most impact-resistant and long-lasting materials used in luggage, and help you choose the right one for your travel needs.

1. Polycarbonate – The Top Choice for Impact Resistance

Polycarbonate is widely considered the best material for hard-shell suitcases due to its combination of strength and flexibility.

• Highly impact-resistant: Can absorb and flex under pressure without cracking.
• Lightweight: Ideal for travelers concerned about airline weight limits.
• Scratch-resistant coatings available: Keeps the suitcase looking newer for longer.
• Great for frequent flyers or those checking luggage often.

Recommended for: Business travelers, international travelers, or anyone needing maximum durability.

2. ABS (Acrylonitrile Butadiene Styrene) – Affordable and Lightweight

ABS is another popular material in hard-shell suitcases, known for its affordability.

• More rigid than polycarbonate, but less durable overall.
• Lighter weight, which helps with airline restrictions.
• Budget-friendly, making it a good entry-level choice.

However, ABS is less resistant to drops and pressure, and may crack with rough handling.

Recommended for: Occasional travelers or short domestic trips.

3. Aluminum – Premium Protection with a Sleek Look

Aluminum suitcases offer exceptional strength and a luxurious aesthetic.

• Extremely durable and crush-resistant.
• Stylish, high-end design, often with reinforced corners and metal locks.
• Heavier than plastic-based materials.
• Easily dented, though the dents are usually superficial and don’t affect function.

Recommended for: Luxury travelers or those carrying delicate or expensive items.

4. Ballistic Nylon – Toughest Soft-Shell Material

For soft-sided suitcases, ballistic nylon is known for its incredible durability.

• Resistant to tears, abrasion, and punctures.
• Lightweight and flexible, making it ideal for overstuffing.
• Doesn’t crack like hard shells, but may lack the protective rigidity.
• Often used in premium business or military-grade luggage.

Recommended for: Business travelers or those who prefer soft-sided luggage with durability.

5. Polyester – Lightweight and Budget-Friendly

Polyester is commonly used in lower-cost soft-sided luggage.

• Lighter and more affordable than nylon, but less durable.
• Prone to wear and tear over time, especially at seams and corners.
• Good for light use and short trips.

Recommended for: Budget-conscious travelers or infrequent use.

Conclusion

When it comes to impact resistance and overall durability, polycarbonate and aluminum stand out among hard-shell materials, while ballistic nylon leads the way for soft-sided suitcases. Consider your travel frequency, handling conditions, and budget to choose the best material. Investing in the right suitcase can protect your belongings and save you from costly replacements down the road.