TL;DR: Full-aluminium body vs aluminium-frame hybrid construction
In B2B luggage sourcing, "aluminium luggage" is the most frequently misquoted term on supplier price sheets. Some trading companies label a suitcase "aluminium" when only the perimeter closure frame is metal and the shell body is polycarbonate or ABS+PC. At DJI Luggage (PT. DJI Travel Products Indonesia · NIB 0710250022508 · KBLI 15121) in Bogor, West Java, Indonesia, we manufacture both true full-aluminium suitcases (stamped 5052/6061 aluminium-magnesium alloy body + frame) and aluminium-frame suitcases (Covestro PC or ABS+PC shell + extruded 5052/6061 frame) at MOQ 100 units per SKU.
| Technical & Commercial Parameter | Full-Aluminium Suitcase (All-Metal) | Aluminium-Frame Suitcase (Hybrid) |
|---|---|---|
| Shell Body Material | Stamped & ribbed 5052 / 6061 aluminium-magnesium alloy sheet (zero plastic panels) | Injection-moulded or thermoformed Covestro PC or ABS+PC polymer shell |
| Perimeter Frame & Corners | Extruded 5052 / 6061 aluminium frame (≥ 40 HWB) + riveted alloy corner guards | Extruded 5052 / 6061 aluminium frame (≥ 40 HWB) + riveted alloy corner guards |
| Assembly & Joining Method | Cold-bent profile and stamped shell riveted at hinges, corners, and latches (never welded) | Extruded profile bent to corner radius and riveted directly through the polymer shell rim |
| Surface Finish | Anodised oxide film (10–12 μm) in silver, black, gunmetal, olive green, blue, red | Micro-diamond matte, high-gloss, or brushed metallic polymer + anodised frame |
| Impact Behaviour | Rigid crush protection; absorbs heavy blows via controlled metal denting (patina) | Polymer shell flexes and rebounds while the 5052/6061 frame prevents mouth distortion |
| Reference Production Series | AURA Full-Aluminium Collection (20" / 24" / 26" / 28") | Voyager & Captain Series (20" / 24" / 26" / 28") |
1. Four specification checks to include on every metal suitcase RFQ
Before comparing unit prices between two factories, require every supplier to state four verifiable numbers on the quotation:
- Exact alloy grade (5052 / 6061): Pure 1000-series or soft 3000-series aluminium bends easily under conveyor impacts. We specify 5052 and 6061 aluminium-magnesium alloys across both extruded frames and stamped metal bodies.
- Case-mouth Brinell hardness ≥ 40 HWB (ISO 6506 / ASTM E10): If the extruded perimeter frame falls below 40 HWB, stacking loads will bow the tongue-and-groove seal and jam the dual TSA latches.
- Riveted vs welded corners: Welding heats the aluminium locally, annealing and softening the heat-treated temper around the corner joint. Riveting preserves the full mechanical strength of the 5052/6061 alloy.
- Anodised oxide film thickness (10–12 μm) and 16-hour salt spray (ISO 9227 / ASTM B117): Thin anodising scratches down to bare metal inside the first month of use and corrodes in humid coastal air. Our 10–12 micrometre anodised finish passes 16 hours of neutral salt spray with no more than three corrosion points each under 1 mm².
2. Why full-aluminium cases require a metal-specific testing protocol
In laboratory quality control, plastic-shell falling-ball and roller-drum impact tests are designed to measure polymer brittle fracture and do not apply to metal-bodied suitcases. At our Bogor facility, full-aluminium suitcases are evaluated against metal-specific mechanical tests: a 900 mm loaded drop onto a solid steel impact plate, a −12 °C four-hour cold conditioning drop, a 4-hour 40 kg / 60 kg static stacking load test, ISO 6506 / ASTM E10 Brinell hardness (≥ 40 HWB), 16-hour ISO 9227 / ASTM B117 salt spray, and SilentMove 360° spinner wheel endurance runs (8 km cement drum + 4 km cleated conveyor, wear ≤ 2 mm; 25 steps at 200 mm). Finished samples are submitted to SGS for third-party test reports. For a deeper dive into frame mechanics, read aluminium luggage explained or request a quote via our contact page.
This is one of five breakdowns on shell material. For the full picture — ABS, ABS+PC, PC, PP and aluminium side by side — start with material choices for hard shell luggage.
Questions buyers ask about full-aluminium vs aluminium-frame suitcases
Why does a full-aluminium suitcase cost significantly more than an aluminium-frame suitcase? A full-aluminium suitcase replaces the injection-moulded plastic shell with stamped, ribbed, and anodised 5052/6061 aluminium alloy sheets and requires precision hand-riveting across every corner cap, hinge, and internal frame mount.
Can we launch a 20" full-aluminium carry-on alongside a 24"/28" aluminium-frame checked set? Yes. Many brands use our ODM AURA full-aluminium 20" carry-on as a halo product while offering colour-matched Covestro PC aluminium-frame checked cases at MOQ 100 units per SKU.
How do you pack anodised full-aluminium suitcases to prevent ocean freight scratches? Each case is sealed in a PE/PP dust bag with EPE foam or non-woven interleaving, reinforced with die-cut corner protectors at all SilentMove wheel housings and handles, and packed with silica gel desiccant inside 5-ply export cartons.
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