What is the toughest luggage material?

Other than aluminum luggage, polycarbonate is the most durable luggage material. Although it's one of the lighter industrial metals, aluminum luggage tends to be heavier than polycarbonate luggage.



The toughest material currently used for hardside luggage is Polycarbonate, specifically "100% Virgin Polycarbonate." This material is prized for its high-fidelity durability because it is designed to flex under pressure and then "pop" back into its original shape, rather than cracking like cheaper ABS plastic. For the absolute maximum in impact resistance and security, Aluminum-Magnesium alloy (famously used by brands like Rimowa and Zero Halliburton) is the gold standard; while it will dent over time, it is virtually impossible to "break" through or slice open. On the softside front, Ballistic Nylon (specifically 1050-denier) is the toughest textile available. Originally developed for military flak jackets, it is incredibly resistant to abrasions, punctures, and tearing. In 2026, many frequent flyers prefer Polypropylene for its lightweight yet rugged properties, but if your priority is "lifetime durability" and protecting fragile items from the brutal environment of airport conveyor belts, a high-grade Aluminum case or a 100% Polycarbonate shell remains the superior choice.

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Aluminum is the most durable and most commonly used material for hard-side luggage because it's lightweight and doesn't rust. Because of its high-quality traits, it comes with a higher price tag. Polycarbonate is also thermoplastic, but it's more rigid than polypropylene and has better impact resistance.

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Polycarbonate is more flexible than ABS and has a higher impact resistance. As a result, it makes for a stronger suitcase. ABS suitcases are cheaper than Polycarbonate ones, but they are often heavier and do not last as long.

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Aluminum is the most durable material for hardside luggage, but it's much heavier than other options and can be pretty expensive. Polycarbonate is the most popular material for hard luggage. It is both lightweight and durable, but it can scratch easily.

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Polypropylene is known for its strength, shock resistance & high density of colour pigments to avoid stress whitening. Samsonite succeeded in creating a range of extremely lightweight polypropylene collections, thanks to new revolutionary polypropylene material called Flowlite.

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Because softshell luggage has more give, a hard shell suitcase can be better at protecting fragile contents, assuming you cushion it well inside. On the other hand, that rigid exterior makes hardshell bags unable to be compressed to squeeze into tight spaces like softsided bags are more apt to allow.

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Swedish pilot Maria Pettersson prefers “half soft-sided” luggage, which offers a bit more support than the typical soft-sided luggage, but provides more flexibility than hard-sided luggage.

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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.

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Hard-shell luggage is the way to go for durability and maneuverability, but soft-shells often pack more easily.

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With an industry leading ABS and Polycarbonate composite shell material and features like a TSA-approved lock on the large size, rest assured that everything in your bags stays neat and secure.

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Samsonite Freeform Carry-on Spinner During our durability tests, the impact-resistant plastic exterior proved to be exceptionally durable after we hit it with a bat several times. We love the simple design of the exterior and there is a TSA-approved lock on the side that's easy to use.

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The main drawback is that hard-shell luggage can't be twisted to fit into a small space. Hard-shell suitcases also require a lot of room to store at home, making them less convenient in this sense.

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Also, hard shells tend to be heavier, but soft-sided ones can damage more easily. There are good and bad features for both and, in the end, it really comes down to personal preference.

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Often considered the most durable type of luggage, a hard shell suitcase has a rigid exterior that is usually made from moulded polypropylene, polycarbonate or ABS plastic, with some using aluminium. They're less flexible than soft-sided suitcases, making them a better option for protecting delicate items.

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The Samsonite Omni PC combines scratch-resistant textures with the polycarbonate construction, ensuring your luggage looks as great on the 100th trip as it does on the first.

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In 1993, American Tourister was acquired by Astrum International, which also owns Samsonite. Astrum was renamed as the Samsonite Corporation two years later. Their products include backpacks, suitcases and wallets. Today, the American Tourister brand is sold as a more affordable brand in the Samsonite portfolio.

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Travelpro Maxlite 5 Softside Carry-On It's no secret that Travelpro is one of the most recommended brands by flight attendants, and this Maxlite 5 softside carry-on is a great example of why.

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Durability and security More and less durability can be found in softsided luggage than hardsided luggage. On the one hand, it is more prone to scratches and stains, harder to clean and less protective of valuables if the bag is thrown or pushed around during transit.

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