Aluminum won’t crack like a polycarbonate shell. You can stomp on these bags and stand on them. Don’t tell airport security, but my daughter and I have been known to race aluminum carry-on bags through airport terminals, like real-life Mario Kart. When frequent travelers buy luggage, they want this structural integrity and reliability. Rigid shells with metal frames and strong latch closures offer better protection for your belongings and should last a lifetime.
Metal rivets, high-quality wheels, robust handles, and better components also mean that all-metal luggage is easier to repair. Well-established brands typically offer generous warranties and repair services, especially on premium cases. Clamshell, zipperless closures are also harder to force open; there’s no zipper fabric that you can sneakily slash through with a pen knife. As with all good-quality luggage brands, the majority now use TSA-approved combination locks, which are not only far more elegant than a clunky old zipper, but add to the confidence these cases afford.
The irony of making a more sustainable purchase while also burning through aviation fuel is not lost on us, but there’s no denying the eco-friendly advantages of aluminum. Recycling aluminum uses up to 95 percent less energy than producing it from raw materials, and it can be easily recycled without any loss of quality.
The longevity of a well-made aluminum case will also mean fewer replacements over time, potentially keeping harder-to-recycle polycarbonate cases out of landfill. Even if you don’t end up buying it for life, aluminum cases also hold their value. Just check eBay.
They’re sexy, desirable, eco-friendly, and long lasting, but aluminum is significantly heavier than the latest polycarbonate equivalent. Most aluminum carry-on bags (standard 22 x 14 x 9 inches as a rule) weigh between 9 and 11 pounds. Of WIRED’s current favorite carry-on luggage, the Rimowa is the second heaviest, behind a 9.7-pound ballistic nylon option from Briggs & Riley.
Photograph: 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 carry-on we’ve found.
This is fine if your airline doesn’t have an official weight limit, but many do, especially budget ones. Flying short-haul in Europe, I’ve become accustomed to my overweight Sterling Pacific case being whisked away to the hold. Carry-on weight limits start from just 15 pounds (Etihad, Emirates, Air New Zealand). After taking into account the bag’s weight, that leaves you with 5 pounds of luggage to pack.
While aluminum provides strength, the rigidity also means you’ll never be able to overpack your carry-on. Expandable nylon designs give you the chance to squeeze in extra layers, or a souvenir or two, but there’s no chance with metal. This isn’t just a problem with aluminum designs. Polycarbonate hard shells have the same issue, although there are a few with external pockets.
Some suitcases have internal compression straps that let you squeeze in more gear. But the buckle fastenings means that, unlike a zipper, there is no give. As I did on a recent trip to Poland, you might have to resort to sitting on the case to get the clasps locked.
In contrast to virtually all other examples of premium product design, owners of aluminum luggage—well, historically Rimowa owners—actually look forward to their $1,500 investment getting battered. Dings, dents, and tatty old stickers are seen as badges of honor, battle scars from a hectic life as an international jet-setter.
It’s just as well, because aluminum is easily scratched and scuffed, and keeping metal luggage pristine for long is a thankless task. If you’re precious about these things, a metal case is not for you. As WIRED’s Martin Cizmar discovered on a recent trip around Europe using a Level8 Gibraltar Aluminum Carry, you will need an auto body technician to get the serious dents out. Polycarbonate designs often bounce back into shape; aluminum does not.
Is Aluminum the Only Option?
Possibly the most used case in my house is the 34-liter D_b_ Ramverk Pro ($749). It combines a rigid aluminum frame with a part-recycled polycarbonate shell and very useful internal laptop sleeve. At 9.9 pounds it isn’t light, but it is extremely tough, and even after five years of regular abuse, it still looks great and performs perfectly.
And if aluminum is too passé for you, Tumi now offers a range of titanium luggage. Starting from a whopping $3,800, it boasts fluid lines and striking looks, but interestingly it weighs more than most (11.6 pounds), despite titanium’s ultralight reputation.
Why They’re Expensive (and Why That’s OK)
Even ignoring the fashion/branding premium placed on them, aluminum carry-ons are expensive. The raw material costs more than molded plastics and is harder to work with. It requires stamping, machining, and finishing, rather than basic injection molding. Construction is also more complex compared to a basic zip bag, with rigid metal frames, latch systems, and reinforced corners. The more parts needed to build it, the more labor and greater manufacturing time required. Better construction also generally means better components and a greater ability to repair.
The up-front cost is high, but if you have a habit of breaking cheap luggage and buying new every few years, you could be better served by a metal carry-on case that lasts for decades. Previous WIRED UK managing editor Mike Dent had his Rimowa case for 16 years. Aluminum cases have become a visible signifier of travel status, with brands like Rimowa actively promoting the unattainably chic aesthetic. This always commands a premium, and it’s not often that highly durable, extremely practical products are also lusted after as luxury goods.
Prices are starting to fall, though. I found the Kangshilu aluminum 20-inch suitcase for just $125, and several options are now under $500. With more manufacturers entering the category, production has scaled, and factories are now more able to produce aluminum shells at volume. Competition is bringing costs down, even if the best-made examples still command a premium.
Are You Really an Aluminum Luggage Person?
If you fly often, value durability, and don’t mind lifting an extra few pounds every time you open the overhead bin, then yes, welcome to the club. Aluminum cases are built to last and capable of taking years of abuse without failing, even if they pick up dents along the way. For frequent travelers, that reliability—and widespread repairability—matters more than pristine looks or marginal weight savings.
There’s also the aesthetic to consider, with aluminum luggage a shorthand for a certain kind of traveler. It carries a fashion-forward high-earner appeal that few practical products manage, where wear and tear adds character and cache.
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