Does aluminium, polycarbonate, or ABS make the best hard-shell suitcase? Each material has strengths and weaknesses—let’s unpack the differences so you can pick the perfect travel companion without second-guessing yourself.
Choosing a hard-shell suitcase is like choosing a travel buddy—you want one that won’t let you down halfway through the journey. You’ve already ruled out soft-shells (good call if you’re after extra protection). Still, now you’re staring at the three most common options: aluminium, polycarbonate, and ABS.
Here’s the deal: the material you choose determines how heavy your case feels when rushing through the airport, how long it lasts after being tossed around by baggage handlers, and even how much it costs.
This guide is built from research, years of travel experience, and a fair bit of trial and error. I’ll break down the pros and cons of each material, who they’re best suited for, and where they fall short. By the end, you’ll know exactly which shell is right for your trips.
Before diving into materials, let’s talk about why travellers love hard-shell suitcases in the first place.
- Protection: They safeguard fragile souvenirs, gadgets, and even a bottle of wine from rough handling.
- Security: Many work better with TSA locks or have built-in latches, making it harder for someone to unzip your bag on the sly.
- Looks: Hard shells tend to look sharper and more modern than their soft-sided cousins.
But remember, the outer shell is only as good as the stuff it’s made from—which brings us back to our three contenders.
Aluminium Luggage: The Classic Heavyweight
Aluminium has been around forever in the luggage world. It’s the stuff you see in those sleek silver cases business travellers roll through first-class lounges. Firm, solid, and undeniably stylish—Aluminium is like the luxury sedan of suitcase materials.
Why People Love It
- Tough as nails: Honestly, it’s the closest thing to armour for your clothes.
- Secure: Many aluminium cases use metal latches instead of zippers—much harder to break into.
- Prestige factor: They look incredible and send a quiet signal: “I travel well.”
- A story in every dent: Instead of scratches, aluminium shows dents. Some travellers hate this, others love the “battle scars.”
Where It Falls Short
- Weight: Heavier than both polycarbonate and ABS—watch those baggage allowance scales.
- Price: You’ll pay a premium. Think investment piece, not impulse buy.
- Dents: While it won’t crack, aluminium does dent, and that polished look fades fast.
If you fly often, travel for business, or love a suitcase that feels like a design statement, aluminium is your match. It’s built for people who don’t mind a bit of extra weight in exchange for near-indestructibility and head-turning style.
👉 Want inspiration? Check out our guide to the best luxury luggage brands.
Polycarbonate Luggage: The Everyday Hero
Polycarbonate is the people’s champion of suitcase materials. It’s lightweight, flexible under stress, and widely considered the best all-rounder. Imagine the kind of rigid plastic used in aeroplane windows or safety gear—that’s polycarbonate.
Why People Love It
- Flexes, doesn’t crack: Perfect for surviving those brutal baggage carousel landings.
- Lighter than aluminium: Easy to hoist into overhead bins without breaking a sweat.
- Options galore: Comes in every colour, pattern, and finish under the sun.
- Good longevity: Strong enough for regular travellers, without the premium price tag.
Where It Falls Short
- Scratches happen: Glossy finishes show scuffs quickly (matte hides them better).
- Not the cheapest: Cheaper than aluminium, pricier than ABS.
Polycarbonate works for just about everyone—families, solo travellers, and frequent fliers alike. If you want a suitcase that balances strength with portability (and don’t mind a few scratches along the way), this is your best bet.
See our list of the best lightweight carry-on suitcases.
ABS Luggage: The Budget Starter Pack
ABS—short for Acrylonitrile Butadiene Styrene (try saying that quickly at check-in)—is the cheapest and lightest of the three. You’ll find it in plenty of budget-friendly luggage lines.
Why People Love It
- Friendly price tag: Easiest on the wallet.
- Light as a feather: Great for short trips or smaller carry-ons.
Where It Falls Short
- Not as tough: Can crack under heavy impact.
- Wears faster: Won’t survive years of frequent flying.
- Feels cheap: It lacks the premium look and feel of the other two.
ABS is ideal for those new to travelling, students, or occasional flyers. It’s the “try-before-you-upgrade” option—great if you don’t want to spend much but still want the benefits of a hard-shell.
👉 For more options, see our picks for the best affordable luggage for budget travellers.
Side-by-Side Comparison -Aluminium vs Polycarbonate vs ABS
Here’s a quick cheat sheet to compare all three:
| Feature | Aluminium | Polycarbonate | ABS |
|---|---|---|---|
| Weight | Heavy | Lightweight | Very lightweight |
| Durability | Super strong, dents | Tough, flexes instead of breaking | Prone to cracks |
| Scratch/Dent | Dents, but holds up | Scratches, especially on glossy finishes | Scratches and cracks easily |
| Price | Premium | Mid-range | Budget |
| Best For | Frequent fliers, luxury lovers | Most travellers | Students, budget travellers |
Polycarbonate strikes the best balance of durability, flexibility, weight, and price for most travellers, while aluminium suits premium frequent fliers, and ABS remains a basic option for budget-conscious students or occasional use.
Insider Tips Before You Buy
- Weight allowance matters: That extra 2–3kg with aluminium might mean leaving your favourite shoes behind.
- Warranties are gold: Brands like Samsonite and Rimowa back their premium cases with strong guarantees—worth the extra spend if you fly often.
- Maintenance tricks: Scratches on polycarbonate? Grab a luggage cover. Dents in aluminium? Wear them like a badge of honour. ABS cracking? Sadly, time for a replacement.
- Think about size: For carry-ons, weight matters less, so even aluminium can work. For big checked luggage, polycarbonate is the best option.
Looking for the right size? Read our carry-on vs. checked luggage guide.
FAQs About Suitcase Materials
Is Aluminium or Polycarbonate Better for Luggage?
It depends on your travel style. Aluminium is stronger and feels incredibly premium—great for business travellers or anyone who wants a suitcase that lasts decades. But it’s heavy and expensive. Polycarbonate, on the other hand, is lightweight, flexible, and still very durable, making it the better choice for most travellers who care about practicality and weight limits.
Which is Better, an ABS or a Polycarbonate Suitcase?
Polycarbonate wins every time. It’s stronger, more flexible, and less likely to crack if thrown around by baggage handlers. ABS is cheaper and works fine for the occasional trip, but for frequent use, polycarbonate will save you the headache of buying replacements.
What to Avoid When Buying Luggage?
A few red flags to watch out for:
- Ultra-cheap ABS suitcases – they often crack quickly.
- Weak zippers or flimsy handles – these fail before the shell does.
- Overly heavy cases – they eat into your baggage allowance before you even start packing.
- No warranty – if a brand doesn’t back up its product, that’s usually a bad sign.
What is the 3-1-1 Rule for Luggage?
The 3-1-1 rule is a TSA guideline for carrying liquids in your hand luggage:
- 3.4 ounces (100 ml) or less per container
- 1 quart-sized, clear, resealable bag
- 1 bag per passenger
It keeps security checks smooth and helps avoid having your favourite shampoo tossed out at the airport.
Why are ABS Suitcases so Much Cheaper Than the Others?
ABS (Acrylonitrile Butadiene Styrene) is a less durable and rigid plastic compared to polycarbonate and aluminium. It’s lighter and less expensive to produce, which allows manufacturers to sell it at a lower price. This makes it a great entry-level option for casual or budget travelers, but it won’t hold up as well under the stress of frequent flights.
Final Verdict: Which Should You Choose?
Here’s the no-nonsense summary:
- Best All-Rounder – Polycarbonate
- If you want something durable, lightweight, and not outrageously expensive, polycarbonate is your winner. It’s why so many travellers swear by it.
- Premium Choice – Aluminium
- For those who value durability and design over weight and cost, aluminium is a long-term investment and a head-turner.
- Budget Pick – ABS
- If you travel occasionally or are on a tight budget, ABS gets the job done. Just don’t expect it to last forever.
At the end of the day, it’s like buying a car. Aluminium is your luxury model, polycarbonate your reliable all-rounder, and ABS your budget-friendly starter. None are “wrong”—it just depends on how often you travel and what you value most.
👉 Still undecided? Check out our guide to the best hard-shell suitcases of the year.
✈️ With the right material, you’ll spend less time worrying about your suitcase and more time enjoying the journey. Safe travels, and may your luggage always arrive when you do!
Drop your choice in the comments. Your comments will help shape our next in-depth luggage comparison!
