How do I choose luggage that lasts?

The four parts that actually fail, hard versus soft on the things that matter, and how to size a case around the airlines you use.

Difficulty: beginner
Time: 40 min
Read: 3 min

Short answer

Luggage fails at the wheels, the handle, the zip and the corners, in that order. Buy for those four things — sealed wheel bearings or replaceable wheels, a handle with no wobble at full extension, chunky coil zips rather than fine ones — and size it to the cabin limits of the airlines you actually fly.

The price of a suitcase correlates poorly with how long it lasts, because most of the money goes on the shell and most of the failures happen everywhere else. A case dies when a wheel seizes or a handle jams, and both are things you can assess in a shop in about a minute.

What you'll need

The cabin dimensions of the airlines you use
Bathroom scales (optional)

Step by step

Check the wheels first, and roll it loaded if you can.Four-wheel spinners are easier on smooth floors and worse on pavements, gravel and cobbles, where two larger recessed wheels win comfortably. Look for wheels that are replaceable — some manufacturers sell wheel kits, which turns a dead case into a repaired one.
Extend the handle fully and push sideways.A handle that wobbles noticeably in the shop will be worse loaded and worse again after a year. Two-pole handles are more rigid than single-pole ones. This is the second most common terminal failure after wheels.
Look at the zip, not the branding.Chunky coil zips with a solid puller and reinforced stitching at the ends survive; fine zips and thin tape do not. A burst zip mid-trip is the failure that actually strands you.
Decide hard or soft on how you travel, not on looks.Hard shells protect fragile contents and resist rain but crack at the corners and cannot be squeezed into a sizer. Soft cases absorb impact, have external pockets and give a little at the gate, but offer less protection and mark more.
Weigh the empty case.The difference between a light and a heavy case of the same size can be several kilograms, and that is several kilograms of allowance you have spent before packing anything.
Size it to the airlines you actually use.Cabin limits differ substantially between carriers and some enforce weight as strictly as dimensions. Buy to the smallest limit you regularly fly, and remember that wheels and handles count in the measurement.
Check the warranty terms and whether parts are sold.A long warranty that excludes airline handling damage is close to worthless. A shorter one with available spare wheels and handles is worth more.
Choose something you can pick out on a belt.Black four-wheel cases all look identical. A distinctive colour, or a bright strap, saves the standing-around and reduces the chance of someone walking off with yours.

Tips

Buy the cabin bag properly and be more relaxed about the hold case. The cabin bag gets dragged across more ground and is the one that has to fit a sizer.
A second-hand premium case with sound wheels and handle is often better value than a new budget one.
Test the case on a rough pavement rather than a showroom floor if you can. Spinner wheels behave completely differently on real surfaces.

Common mistakes

Buying the largest case available — It fills, and then it exceeds the weight allowance long before it is full. A big case mostly buys you excess baggage charges.
Judging quality by the shell — Shells rarely fail in a way that ends a case. Wheels, handles and zips do, and they are what to inspect.

Questions people ask

Hard shell or soft case?

Hard shells protect fragile items and shrug off rain but crack at the corners and cannot be compressed into a sizer. Soft cases flex, have useful outer pockets and survive rough handling better, at the cost of protection. Choose on how you travel rather than appearance.

Are four wheels better than two?

On airport floors, yes. On pavements, cobbles, gravel or stairs, two larger recessed wheels pulled behind you are much better. Pick for the ground you cross most.