Selecting the ideal carry-on suitcase is more nuanced than simply ensuring it fits overhead or beneath your seat. To help discerning travelers navigate the benefits and drawbacks of today’s most sought-after luggage materials, we consulted Magnus Nilsson, Sales Manager at TUMI, a global leader in premium travel gear.

Aluminum cabin luggage exudes sophistication and is prized for its contemporary, high-end appeal. Polycarbonate offers impressive resilience and featherlight construction, though it may sacrifice some durability compared to its metal counterparts. Ballistic nylon, meanwhile, is renowned for its flexibility and weight savings. We asked TUMI to break down the real-world performance of these materials—each of which features in their latest collections.

“Every material brings unique strengths and limitations; the best choice depends on your travel style and expectations,” Nilsson explains. “Aluminum is exceptionally sturdy, maintains its form, and looks luxurious. However, it’s susceptible to dents from rough handling and typically weighs over 4 kg empty. If your carry-on is gate-checked, it’s more likely to sustain cosmetic marks in the hold. Aluminum cases also command a premium price. On the upside, if you’re traveling in First or Business Class on long-haul routes, you’re unlikely to encounter issues with a 9 kg carry-on.”

So, how does polycarbonate compare? “Polycarbonate is perfect for travelers seeking a tough yet ultralight suitcase,” Nilsson says. “TUMI’s polycarbonate models feature expandable designs, letting you maximize packing space without compromising protection against knocks. The material’s main drawback is vulnerability to cracking in extreme cold—think temperatures far below zero. We’re also seeing growing interest in SRPP (Self Reinforced Polypropylene), which is exceptionally robust, lighter still, and crafted from recycled sources. The only caveat is its higher cost, due to the advanced recycling involved.”

And what about ballistic nylon? “Ballistic nylon remains a favorite for those who prioritize weight savings and flexibility,” Nilsson shares. “It’s ideal for travelers aiming to pack generously while remaining under typical 8 kg cabin limits. While highly resistant to abrasion and tearing, it doesn’t quite match the longevity of aluminum or advanced composites.”