Quick Verdict: When choosing hardside luggage, polycarbonate is the most durable and impact-resistant but comes at a higher price and heavier weight. Polypropylene is the lightest option available, offering an excellent balance of affordability and durability. ABS is the cheapest and most rigid material, but it is the least durable and most prone to cracking. For frequent flyers, polycarbonate is the best long-term investment, while polypropylene is ideal if you need to strictly minimize checked baggage weight.
The shell material decides how much abuse a suitcase survives, how much it weighs empty, and how much it costs. Polypropylene, polycarbonate, and ABS are the three plastics behind almost every hardside bag, and they behave differently enough that the types of hardside luggage you pick can make or break a trip.
This guide compares all three shells on durability, weight, price, and design, then names specific suitcases worth buying in each material so you can match the shell to how you actually travel.
What is ABS luggage, and which shell is best? ABS (acrylonitrile butadiene styrene) is a rigid, low-cost hard plastic used in most budget suitcases. Of the three hardside shells, polycarbonate is the most durable because it flexes on impact instead of cracking, polypropylene is the lightest and the best value under strict weight limits, and ABS is the cheapest but the most brittle. Choose polycarbonate for frequent checked-bag travel, polypropylene when every pound counts, and ABS for occasional or carry-on trips on a tight budget. If you want to see how one brand handles the shell trade-off in practice, our Beis luggage review covers where its polycarbonate line lands.
Comparison Table
Here is a quick comparison of the key differences between these materials:
| Material | Pros | Cons |
|---|---|---|
| Polycarbonate | Strong, Durable | Expensive, Heavier |
| Polypropylene | Light, Affordable, Durable | Less Durable, UV Degradation |
| ABS | Affordable, Lightweight | Less Durable, Less Strong |
Whether you are traveling domestically or internationally, there are several guidelines that you must always adhere to at the airport. The size and weight of your luggage are the top two that you should pay close attention to unless you don’t mind paying a huge additional fee.
The right polycarbonate, polypropylene, or ABS luggage for your needs will help ensure your checked suitcase is of the right weight. Since you don’t need a collection of suitcases at home, take your time to find the right fit. So, what’s the best material between polypropylene, polycarbonate, and ABS luggage?
Detailed Material Analysis
Let’s examine the differences between these hard-side luggage materials used in making travel suitcases in more detail.
Polycarbonate Luggage
Most major brands offer polycarbonate luggage options in their catalogs. These are travel suitcases made of thermoplastic polymers that contain carbonate groups in their chemical structures. Polycarbonate materials are easy to work with, mold, and thermoformed into different products, including hard-side luggage material and bulletproof glass.
Pros
- Very reliable
- Durable, and can withstand any abuse
Cons
- Very expensive
- Heavier and may be harder to transport
Polypropylene Luggage
Polypropylene luggage is made from thermoplastic polymers through the chain-growth polymerization of mono polymers. They lie between polycarbonate plastic and ABS luggage, giving them the best of both worlds. They are more durable than ABS and lighter than polycarbonate luggage.
Pros
- Temperature and chemical-resistant
- Affordable
- Lightest (even lighter than aluminum luggage)
- Good for frequent use
Cons
- Less durable than polycarbonate luggage
- Susceptible to UV degradation
ABS Luggage
ABS plastic luggage is made of a thermoplastic called ABS (acrylonitrile-butadiene-styrene). This is a cheap hard material, which makes it popular among cheaper hard-side luggage.
Pros
- Affordable
- Rigid, holds its molded shape
- Lightweight
Cons
- Less durable
- Not as reliable
Direct Comparisons
Comparing the different types of travel luggage on the market is a key component of making a more informed decision about which suitcase to invest in. Since your carry-on will be safe with you most of the time, below is a comparison of the three main types of checked traveling luggage.
Polypropylene vs Polycarbonate Luggage
The main difference between polypropylene and polycarbonate luggage is the heaviness of the material used in manufacturing polycarbonate bags, which makes them much heavier than polypropylene suitcases.
This thick material makes the suitcases more durable and increases their resistance to impact and scratches. It also makes polycarbonate bags much more expensive than their counterparts’ polypropylene bags.
On the other hand, polypropylene luggage is more lightweight and affordable as compared to polycarbonate suitcases.
Polycarbonate vs ABS Luggage: Which Is Better?
Polycarbonate is significantly better than ABS luggage for durability, impact resistance, and longevity. While ABS is cheaper and lighter upfront, it is rigid and brittle — meaning it is prone to cracking when dropped, crushed under heavy suitcases, or subjected to freezing airplane cargo holds. Polycarbonate absorbs heavy impacts by flexing and popping back into shape, making it the superior investment for frequent flyers and checked baggage.
A key difference between polycarbonate luggage and ABS luggage is their flexibility. Polycarbonate bags also have a higher impact resistance than ABS suitcases.
ABS bags are more affordable in terms of pricing, but they lose the race regarding usage and durability. If you are not a frequent traveler, these ABS bags will serve you well – albeit for a shorter period – if you are not a frequent traveler.
Though not as strong or durable as polycarbonate luggage, some blends or ABS luggage can serve well – especially if used with care and without abuse. If you are deciding between high-end shells, you can see whether TUMI is worth the premium for its ultra-tough Tegris and ballistic nylon options, or read our Away luggage review for a popular direct-to-consumer polycarbonate suitcase.
Polypropylene vs ABS Luggage
ABS (5500 psi) has a higher tensile strength than polypropylene (4000 psi), making it stronger and harder. However, this doesn’t translate to more durable luggage. The rigidity of ABS makes it more prone to cracks, thus decreasing its lifespan.
This makes flexibility the major difference between polypropylene and ABS luggage. Flexibility means more resistance to impact and cracks, translating into longer durability. Investing in a flexible travel suitcase will save you money in the long run.
See Related: Away Luggage Review: Is It Worth it?
Top Luggage Recommendations
Now that you are well informed about the pros and cons of the several types of travel luggage and their main comparisons let’s look at some examples of travel suitcases on the market. Here are some of our top picks in each category.
| Best Overall | Away |
| Most Affordable | AmazonBasics |
| Best Design | LEVEL8 |
| Best for Professional Travelers | Travelpro |
Amazon Basics 21″ Hardside Spinner Luggage
The Amazon Basics Hardside Spinner Luggage is polycarbonate and has some great features that help make your travel less stressful. It’s equipped with a built-in TSA lock that makes it easier to inspect airport security, saving you some time.
Its protective hard shell is durable and flexible, ensuring your goods are safe and sound. The four double-spinning wheels will ease your movements through the airport and to your destination.
This suitcase can expand by another 15% of its packing capacity. This will give you more room to squeeze in those books you want to take on vacation or even your portable safe to secure your phones, money, and credit cards.
It has a three-digit code lock that you can set easily for added security. There are also zippered interior pockets where you can securely pack small items.
See Related: Monos Luggage Review: Is it Worth it?
Samsonite Omni PC Hardside Luggage
This Samsonite Omni PC Hardside Luggage is made from micro-diamond polycarbonate, which makes it extremely scratch-resistant. The casing will keep your suitcase looking as good as new, even on your 50th trip.
This Polycarbonate luggage meets most domestic weight travel restrictions, with packing dimensions of 19″ x 14.4″ x 9.5″ and a weight of only 6.81 pounds.
Samsonite products undergo rigorous testing to ensure that you get your money’s worth, and they also offer a 10-year limited warranty- you can only get a replacement if the workmanship or materials are defective.
It comes with TSA locks mounted on the side to deter thieves and allow easy inspection at the airport. Do you have some extra items to pack? Don’t worry. This baby can expand to accommodate additional items and even has compression belts to keep your clothes neatly pressed.
The handle has a push button that extends it when in use and retracts it when not in use. This keeps everything neat on your flight or in the cab driving to the hotel.
See Related: Delta Airlines Review
DELSEY Paris Chatelet 24″ Hardside Luggage
This 24-inch DELSEY Paris Chatelet Hardside Luggage is made of 100% polycarbonate to ensure maximum resilience to cracking and increase durability. Its design also includes stylish faux leather accents that make it stand out.
It is TSA-approved and has a recessed 3-dial lock for more security. It’s the perfect suitcase for long business trips or vacations, and its recessed one-button locking handle increases maneuverability while you’re on the move.
The suitcase’s interior has web straps that keep your items secure and wrinkle-free in the two large compartments. To top it all up, it has detachable bags for laundry and shoes and a hanger for your shirts.
This travel suitcase has four spinner wheels that offer multidirectional rolling and a stable base for your luggage. The two front wheels have a great braking system that keeps your suitcase from rolling away while in use.
Have you lost your DELSEY Paris Chatelet Hardside Luggage? No worries. It comes with a tracking device that will enable you to locate it in minutes. Like all the Chatelet models, it has a 10-year limited warranty.
Samsonite Freeform Hardside Expandable Luggage
Great for light traveling, the Samsonite Freeform Hardside Expandable Luggage has packing dimensions of 19.5″ x 14.5″ x 10.0″ and weighs 6.5 pounds. Though light, it has an ultra-strong shell that can withstand the rigorous movements of traveling domestically or abroad.
The four multidirectional wheels provide ease of movement and, by rolling while upright, relieve any strain on your arm or shoulder.
It’s got room for expansion to maximize space fully and compression straps to keep your clothes neatly pressed – you can land and head straight into a meeting with a shirt without creases.
Their handles have push-button locking mechanisms that keep your suitcase neat when you aren’t using it. They also come in various colors that you can choose to match your style.
It has a 10-year limited warranty against defective workmanship and materials. Destruction from abuse, falling, or scratches isn’t covered under the warranty – though the rigorous testing it’s put through ensures that you get the best product for your money.
See Related: Best Travel Routers
Traveler’s Choice Pagosa Expandable Luggage
Built with an indestructible polypropylene hard shell, the Traveler’s Choice Pagosa Expandable Luggage is another great travel companion for your next business trip or vacation. The hard shell makes it water, scratch, and abrasion-resistant, making it very durable.
This 26″ medium-sized travel suitcase weighs 8.24 pounds and has interior dimensions of 23.5″ x 16.5″ x 10.5″. The large compartment inside has a compression strap that will keep your clothes neat and in place. There are also zippered (self-mending zips) pockets for storing small personal items.
It also has an expansion gusset that adds up to 2 inches of packing space. This will come in handy when you debate what to take with you and what to leave behind.
Starting your trip on a positive note is a great motivator, and leaving something you were sure you needed isn’t the best first step to a great holiday.
The 360-degree wheels drastically improve the maneuverability of your polypropylene luggage. You can move easily through crowds without apologizing or straining your arms from lack of control.
Its multi-stage telescoping handle makes it easy for people of different heights to use. It also has a rubber side and top carry handles for easy lifting and carrying.
See Related: Best Travel Drones
Coolife Luggage Expandable
These suitcases are made from a hybrid of polycarbonate and ABS materials for toughness and durability. They’ve undergone serious testing and adhere to high-quality control standards to produce a great product that can withstand rough handling.
Coolife Expandable Luggage comes in three different sizes: 20″, 24″, and 28″. It has a 2-year warranty. Only 28″ luggage has an additional expandable space of 15% of the useable space.
This baby has multi-use interior pockets for organizing your belongings. It is also fully lined, which makes packing your clothes a breeze.
Lastly, it has spinner wheels for ease of movement and a 3-level telescoping adjustable handle made of pure aluminum, which is great for maneuvering.
See Related: Best Herschel Travel Bags
Kono Carry-on Suitcase
The Kono carry-on suitcase is a superb choice if you are looking for stylish ABS luggage. It comes in several colors, new designs, and exquisite hardware, giving it a stylish new look.
Its high-quality shell is light, waterproof, and fairly durable – especially since you don’t have to check it if you don’t want to. It’s lightweight and helps you avoid unnecessary extra charges at the airport. It weighs a mere 4.4 pounds and is 20″ long.
Easy movement courtesy of the 3-level telescoping handle with a comfortable grip and 360-degree wheels that give you a smooth ride even on rough roads. It rolls upright, making it less stressful on your arms when you are moving.
It has a 3-digit lock that will keep your luggage secure and a 3-level adjustable handle for ease of use by both grownups and kids.
See Related: Best Gifts for Pilots and Aviation Enthusiasts
Buying Guide (Factors to Consider)
With all the different types and brands of travel suitcases on the market, you must find one that perfectly suits your needs before you “add to your cart.” I have compiled a shortlist of factors to consider when choosing a suitable travel suitcase. Let’s go check them out!
Size
The first thing you should consider is the size of the luggage. This will depend on the amount of luggage and your destination; if you are going on a business trip, you might not need as much space as if you were going on vacation.
Whether you opt for polypropylene, polycarbonate, or ABS luggage, they all come in different sizes. So you don’t have to compromise on the luggage size you want.
Durability
The most durable luggage for travel is polycarbonate. It’s heavier-duty plastic and sturdy material resistant to scratches and falls.
Airport luggage handlers aren’t always gentle when moving traveling bags; if you have something fragile, a polycarbonate suitcase might be the way to go.
It’s closely followed by polypropylene luggage, designed to be chemical and temperature-resistant. Minor falls and overzealous baggage handlers won’t damage your luggage, though the effects will become visible over time.
ABS luggage is the least durable due to its light material. However, some ABS blends are on the market if you want to invest in a stronger one.
Weight
Polycarbonate luggage is the heaviest due to the sturdy and strong plastic material used in its manufacturing. Heavy materials mean that anything you pack in this luggage will be safe and secure no matter how it’s handled at the airport.
ABS is second in weight. It’s a great option if you are looking for something light but don’t plan on using it often. Polypropylene plastic is the lightest suitcase on the market. It’s made of a thermoplastic polymer that’s quite strong but lightweight, making a polypropylene suitcase even lighter than aluminum suitcases.
Cost
The next thing to consider is the price. The price of a travel suitcase will vary depending on the size, color, materials, brand, and features. The most affordable of the three is the ABS suitcase, made from cheaper material; it is great for someone who doesn’t travel a lot and is looking for a low price tag.
Polypropylene and polycarbonate suitcases are more moderately priced and last for years, saving you money on replacements over the long run.
Some features and add-ons that might make two suitcases of the same size and from the same brand vary, including wheels and easy locks.
Design
Design differences between ABS, polypropylene, and polycarbonate luggage are another important factor to consider.
This includes subtle differences such as TSA locks, extra-thick materials, expansion zippers, and multidirectional wheels. Though they can all be used to carry your traveling products, designers add these features to make them more convenient.
With the information provided here, you are now in a much better position to discern the best luggage for travel between abs, polypropylene, or polycarbonate travel luggage.
FAQs
Which is better: ABS or polycarbonate luggage?
Polycarbonate is generally better than ABS because it is highly flexible and impact-resistant, meaning it will bend rather than crack under heavy pressure. However, ABS is more affordable, making it a good choice for budget-conscious travelers who don’t fly frequently.
Does ABS luggage crack easily?
Yes, compared to other hard-shell materials, ABS luggage is more prone to cracking. Because it is a rigid plastic with less flexibility than polycarbonate, it can crack or shatter if subjected to heavy impacts or rough baggage handling at the airport.
Is polypropylene luggage better than ABS?
Yes, polypropylene is generally better than ABS. Polypropylene is lighter, more flexible, and more durable than ABS, making it much less likely to crack. It is an excellent middle-ground option that balances durability, low weight, and affordability.
What is the lightest hard shell luggage material?
Polypropylene is the lightest hard-shell luggage material available on the market. It is significantly lighter than both polycarbonate and ABS, making it the best choice if you are trying to maximize your packing weight while staying under strict airline baggage limits.
What does ABS stand for in luggage?
ABS stands for acrylonitrile butadiene styrene, a rigid, low-cost thermoplastic used in most budget hardside suitcases. It is lightweight and molds easily, but it is the most brittle of the common hard-shell materials, so it is more likely to crack under rough baggage handling than polycarbonate or polypropylene.
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