Soft Versus Hard Shell Hard shell suitcases can crack, which causes them to fall apart more rapidly than soft luggage. To avoid this concern choose a suitcase made from polycarbonate ABS that stands up to the rigors of travel. The FERGE brand makes a TSA-lockable suitcase on wheels using polycarbonate ABS.

Yes, hard-shell suitcases can crack, but the likelihood depends entirely on the material. In 2026, the industry distinguishes between ABS plastic (which is rigid and prone to cracking under heavy impact) and 100% Polycarbonate (which is designed to flex and "bounce back" from blows). Most "cracking" issues occur with cheaper, brittle ABS luggage when it is handled roughly by automated sorting systems or thrown onto a cold tarmac. Higher-end polycarbonate or aluminum cases are far more resilient. To prevent cracking, it is a recommended practice to not under-pack your hard-side bag; leaving large empty spaces inside makes the shell more vulnerable to caving in when other heavy bags are stacked on top of it. Many modern manufacturers now offer "lifetime warranties" that specifically cover shell cracks, reflecting the significant improvements in material durability over the last decade.