Durable Suitcase Materials Compared: Aluminum vs Polycarbonate vs Polypropylene

Choosing a suitcase built to last can make all the difference on long-term travel or frequent flights. 

In this guide, we break down the top materials that deliver superior durability, impact resistance, and value—helping you make a smart investment.

Aluminum: The Ultimate in Rigidity

Strength: Recognized as the toughest suitcase material—aluminum bends rather than cracks under pressure.

Drawbacks: Heavy, expensive, and easily dented—scratches and scuffs are very visible.

Best For: Luxury travelers, fragile gear, or long haul trips where protection is priority.

Polycarbonate: Balanced Durability & Flxibility

Strength: High impact resistance—flexes on impact and returns to shape without cracking.

Weight: Lighter than aluminum while remaining robust.

Scratch Resistance: Better at hiding wear; some use dyed-through shells to reduce visible marks.

Drawbacks: Pricier than ABS or polypropylene; heavier than the lightest options.

Best For: Frequent flyers who need dependable protection without excess weight.

Polypropylene (PP): Ultra-Light & Affordable

Weight: The lightest hard-shell option available.

Durability: Good flexibility and crack-resistance; though not as tough as polycarbonate.

Drawbacks: More prone to scratches and can degrade in extreme temperatures; often perceived as low-end.

Best For: Budget-conscious travelers looking for lightweight, dependable protection.

ABS (Acrylonitrile Butadiene Styrene): Cheapest Hardware Option

Cost: Most affordable hard-shell material, frequently blended with others for cost savings.

Durability: Rigid but less flexible—more prone to cracking under stress.

Best For: Infrequent travelers or ultra-budget purchases with minimal expected abuse.

Soft-Shell Fabrics: Nylon, Ballistic Nylon & Polyester

Strength: Ballistic nylon scores highest among fabrics for abrasion resistance; polyester is lighter and more affordable.

Advantages: Expandability, external pockets, flexible packing and lower weight.

Disadvantages: Less protection against impacts, seams can tear under heavy stress.

Best For: Travel that requires versatile packing, external storage, or flexibility.

Comparison Table

Material	Durability	Weight	Impact Resistance	Scratch Visibility	Price Range
Aluminum	Very High	Heavy	Excellent rigidity	High	$$$$
Polycarbonate	High	Moderate-Low	High flexibility	Moderate	$$–$$$
Polypropylene (PP)	Moderate	Very Light	Good bounce-back	Moderate–High	$–$$
ABS	Low–Moderate	Light	Low crack resistance	Moderate	$
Ballistic Nylon	Moderate–High	Light	Limited, fabric-based	Low	$$–$$$

Final Recommendations

• Best Overall Performer: Polycarbonate—balances strength, flexibility, weight & price.

• Premium Protection: Aluminum—ideal when impact resistance and aesthetics outweigh weight/price concerns.

• Lightweight Budget Option: Polypropylene—best for travelers needing light, reliable gear without high cost.

• Flexibility & Features: Soft-shell fabrics—great for expandability, pockets, and lighter packing.