Aluminum will not crack like a polycarbonate shell. You can step on these bags and stand on them. Don’t tell airport security, but my daughter and I have been known to chase aluminum carry-on bags through airport terminals, just like in real life. Mario Kart. When frequent travelers buy luggage, they look for structural integrity and reliability. Hard shells with steel frames and strong latch closures offer better protection for your belongings and should last a lifetime.
Steel rivets, high-quality wheels, strong handles, and better parts mean that all-steel luggage is easy to maintain. Well-established brands usually offer extensive warranties and repair services, especially in premium cases. Clamshell, zipperless closure is also difficult to force open; There’s no fabric zipper you can’t sneakily cut with a penknife. As with all types of good quality luggage, most now use TSA approved combination locks, which are not only better than the old loose zipper, but add so much confidence to these cases.
The paradox of making sustainable purchases while burning jet fuel is not lost on us, but there’s no denying aluminum’s eco-friendly benefits. Recycling aluminum uses 95 percent less energy than producing it from raw materials, and it can be easily recycled without losing quality.
The longevity of a well-made aluminum case will also mean fewer replacements over time, which can keep hard-to-reuse polycarbonate cases out of waste. Even if you don’t end up buying it for the rest of your life, aluminum cases also hold their value. Just check eBay.
They are attractive, attractive, environmentally friendly, and durable, but aluminum is heavier than the latest polycarbonate equivalents. Most aluminum carry-on bags (typically 22 x 14 x 9 inches) weigh between 9 and 11 pounds. In WIRED’s current favorite carry, the Rimowa is the second heaviest, behind the 9.7-pound ballistic nylon option from Briggs & Riley.
Photo: Adrienne So
In comparison, the Samsonite C-Lite Spinner ($500) weighs just 4.5 pounds, and the Travelpro Maxlite Air V2 ($195) weighs just 6.4 pounds. At 9.5 pounds, the Rimowa is the lightest aluminum we’ve found.
This is great if your airline doesn’t have a legal weight limit, but many do, especially budget ones. Flying short-haul in Europe, I’ve gotten used to having my overweight Sterling Pacific case taken to the hold. Carry-on weight limits start from just 15 kilograms (Etihad, Emirates, Air New Zealand). After factoring in the weight of the bag, that leaves you with 5 pounds of luggage to pack.
While aluminum provides strength, durability also means you’ll never be able to overpack what you’re doing. Designs with stretchy nylon give you the option to squeeze in extra layers, or a souvenir or two, but there’s no chance with metal. This is not just a problem with aluminum designs. Polycarbonate hard shells are a similar story, although there are a few with external pockets.
Some suitcases have internal straps that allow you to squeeze in extra gear. But buckle fastenings mean that, unlike a zipper, there is no give. As I did on a recent trip to Poland, you may have to resort to sitting on the case to get the pins locked.
Unlike almost every other example of premium product design, aluminum luggage owners—well, Rimowa owners historically—actually look forward to banging back their $1,500 investment. Dings, dents, and faded old stickers appear like badges of honor, scars from the busy life of an international jet-setter.
That’s right, because aluminum is easily scratched and scratched, and keeping metal luggage clean for a long time is a thankless task. If you are precious about these things, the metal case is not for you. As WIRED’s Martin Cizmar found out on a recent trip around Europe using the Level8 Gibraltar Aluminum Carry, you’ll need an auto body expert to remove the sensitive dents. Polycarbonate designs often return to form; aluminum does not.
Is Aluminum The Only Option?
Probably the most used case in my house is the 34-liter D_b_ Ramverk Pro ($749). It combines a strong aluminum frame with a recycled polycarbonate shell and a very useful internal laptop sleeve. At 9.9 pounds it’s not light, but it’s very heavy, and even after five years of regular abuse, it still looks great and works great.
And if aluminum is too much for you, Tumi now offers a range of titanium luggage. Starting at a cheap $3,800, it has fluid lines and a stunning look, but interestingly it weighs more than most (11.6 kilograms), despite the reputation of titanium.
Why They’re Expensive (And Why That’s OK)
Even ignoring the fashion/product premium placed on them, aluminum carriers are expensive. Raw material is more expensive than molded plastics and difficult to work with. It requires stamping, machining, and finishing, rather than basic injection molding. The construction is also more sophisticated compared to the basic zip bag, with strong metal frames, latch systems, and reinforced corners. When more parts are needed to build, more labor and more production time are required. Better construction also usually means better parts and greater repairability.
The upfront cost is high, but if you’re in the habit of breaking out cheap luggage and buying new ones every few years, you might be better off with a steel case that lasts for decades. WIRED UK managing editor Mike Dent had his Rimowa case for 16 years. Aluminum cases have become a visual representation of the travel scene, with brands like Rimowa promoting an unattainable chic aesthetic. These always cost a premium, and it’s not often that durable, highly functional products are sought after as luxury goods.
Prices are starting to come down, however. I found a 20-inch Kangshilu aluminum suitcase for just $125, and several options are now under $500. As more manufacturers enter the segment, production has increased, and factories are now able to produce aluminum shells in volume. Competition is something to keep costs down, even if the best-made examples still command a premium.
Are You Really An Aluminum Person?
If you fly regularly, appreciate durability, and don’t mind lifting a few extra pounds every time you open the overhead bin, then yes, welcome to the club. Aluminum cases are built to last and can take years of abuse without failure, even if it picks up dents along the way. For frequent travelers, that reliability—and widespread adjustability—is more important than clean looks or weight savings.
There is also beauty to consider, with aluminum luggage being shorthand for a certain type of traveler. It carries a high-end fashion-forward appeal held by few tangible products, where aging adds character and preservation.
