Do You Need Aluminum Luggage? (2026): Rimowa, Away, Carl Friedrik

Aluminum will not 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, just like in real life. Mario Kart. When frequent travelers purchase luggage, they look for this structural integrity and reliability. Hard cases with metal frames and strong latch closures provide better protection for your belongings and should last a lifetime.

Metal rivets, high-quality wheels, sturdy handles and better components also mean that all-metal luggage is easier to repair. Well-established brands generally offer generous warranties and repair services, especially on high-end cases. Clamshell and zipperless closures are also more difficult to force open; there is no zippered fabric that you can sneakily cut with a pen knife. As with all good quality luggage brands, the majority now use TSA approved combination locks, which are not only much more stylish than a bulky old zipper, but also add to the confidence these suitcases provide.

The irony of making a more sustainable purchase while burning aviation fuel isn’t lost on us, but there’s no denying the environmental benefits of aluminum. Recycling aluminum uses up to 95% less energy than producing it from raw materials, and it can be easily recycled without any loss of quality.

The longevity of a good quality aluminum enclosure will also mean fewer replacements over time, which could prevent polycarbonate enclosures, which are harder to recycle, from ending up in landfills. Even if you don’t buy it for life, aluminum cases also retain their value. Just check eBay.

They’re sexy, desirable, eco-friendly and durable, 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. Among WIRED’s favorite carry-on bags, the Rimowa is the second heaviest, behind a 9.7-pound ballistic nylon option from Briggs & Riley.

Photography: 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. Weighing 9.5 pounds, the Rimowa is the lightest aluminum carry-on bag we’ve found.

It’s fine if your airline doesn’t have an official weight limit, but many do, especially economy airlines. When traveling short distances in Europe, I became accustomed to my overweight Sterling Pacific suitcase being taken in the hold. Carry-on weight limits start from just 15 pounds (Etihad, Emirates, Air New Zealand). After factoring in the weight of the bag, that leaves you with 5 pounds of luggage to carry.

Although aluminum offers strength, its rigidity also means that you will never be able to overload your carry-on bag. Stretchy nylon models give you the option of inserting extra layers, or a keepsake or two, but there’s no chance with metal. This isn’t just a problem with aluminum designs. Polycarbonate hard cases have the same problem, although there are a few with external pockets.

Some suitcases have internal compression straps that allow you to fit more gear. But buckle closures mean that, unlike a zipper, there is no crease. As I did on a recent trip to Poland, you may need to sit on the case to lock the clasps.

Unlike virtually every other example of premium product design, aluminum luggage owners – well, historically Rimowa owners – wait with bated breath for their $1,500 investment to be demolished. The dings, dents and faded old stickers are considered badges of honor, battle scars from a hectic life as an international jet-setter.

This is just as well, because aluminum is easily scratched and scuffed, and keeping metal luggage intact for a long time is a thankless task. If these things matter to you, a metal case is not for you. As WIRED’s Martin Cizmar discovered on a recent trip through Europe using a Gibraltar Level 8 aluminum rack, you’ll need an auto body technician to remove serious dents. Polycarbonate designs often spring back into shape; aluminum does not.

Is aluminum the only option?

Perhaps the most used case in my house is the 34-liter D_b_ Ramverk Pro ($749). It combines a rigid aluminum frame with a partially recycled polycarbonate shell and a useful internal laptop sleeve. At 9.9 pounds, it’s not lightweight, but it’s extremely durable and even after five years of regular abuse, it still looks great and works great.

And if aluminum is too outdated for you, Tumi now offers a range of titanium luggage. Starting at $3,800, it features flowing lines and a striking look, but interestingly, it weighs more than most (11.6 pounds), despite titanium’s ultralight reputation.

Why They’re Expensive (And Why They’re OK)

Even ignoring the fashion and brand premium placed on them, aluminum carry-on luggage is expensive. The raw material costs more than molded plastics and is more difficult to work with. This requires stamping, machining and finishing, rather than basic injection molding. The construction is also more complex compared to a basic zip bag, with rigid metal frames, locking systems and reinforced corners. The more parts it takes to build it, the more labor and manufacturing time it takes. Better construction also generally means better components and greater repairability.

The initial cost is high, but if you’re used to breaking in cheap luggage and buying new ones every few years, you might be better served by a metal carry-on suitcase that lasts for decades. Former WIRED UK editor Mike Dent had his Rimowa case for 16 years. Aluminum cases have become a visible symbol of traveler status, with brands like Rimowa actively promoting this incredibly chic aesthetic. It’s always expensive, and it’s rare that extremely durable and extremely practical products are also considered luxury products.

But prices are starting to fall. I found the Kangshilu 20-inch Aluminum Suitcase for just $125, and several options are now under $500. With more manufacturers entering this category, production has increased and factories are now more able to produce aluminum hulls in volume. Competition East keep costs down, although the best-made examples still command a premium.

Are you really an aluminum luggage lover?

If you travel often, value durability, and don’t mind lifting a few extra pounds every time you open the overhead compartment, then yes, welcome to the club. Aluminum cases are built to last and able to withstand years of abuse without breaking down, even if they take some bumps along the way. For frequent travelers, this reliability and widespread repairability matter more than impeccable appearance or marginal weight savings.

There’s also aesthetics to consider, with aluminum luggage being a shortcut for a certain type of traveler. It conveys an edgy, lucrative appeal that few practical products manage, where wear and tear adds character and cachet.