The biggest disadvantage is their high price - certainly higher than plastic or glass and as a result, customers opt for Acrylonitrile Butadiene Styrene (ABS) which is tougher, but not impact and heat resistant.

While polycarbonate is a top-tier material for hard-shell luggage, its primary disadvantage in 2026 is its higher price point compared to ABS or polypropylene alternatives. Another drawback is that it is more prone to surface scratches; while the material is extremely impact-resistant and won't easily crack, the glossy finish on many polycarbonate bags can show scuffs and "character" after just a few flights. Additionally, polycarbonate is heavier than polypropylene, which can be a concern for travelers trying to stay strictly under airline weight limits. Because polycarbonate is designed to be flexible and "flex" under pressure to prevent cracking, some users find the shell feels "flimsy" compared to a rigid aluminum or thick ABS case, even though it is actually much more durable and likely to survive a drop or rough handling by baggage staff.