Die-Stamped 5052/6061 Sheet Skins
Progressive cold-stamping forms deep structural ribs into 5052/6061 aluminium-magnesium sheet, delivering a 3.7 kg 20-inch metal body stable from -40 °C to 120 °C.
Across the global luggage trade, the phrase “aluminium suitcase” is frequently blurred: many suppliers advertise an “aluminium case” when the body is actually thermoformed polycarbonate riveted to an aluminium closure ring. In our Bogor factory, we draw a strict metallurgical line across our four collections: Captain Aluminum Frame, Captain Zipperless, and Voyager use Covestro polycarbonate / ABS+PC shells mated to an alloy frame, whereas the AURA Collection is a true full-aluminium (full aluminium) suitcase. Both the ribbed clamshell skins and the perimeter mouth frame are fabricated from 5052/6061 aluminium-magnesium alloy.
How does a full-metal 20-inch suitcase weigh 3.7 kg — 0.34 kg lighter than our 4.04 kg Captain Aluminum Frame PC case and 1.15 kg lighter than our 4.85 kg Captain Zipperless PC case? The answer lies in progressive die-stamping and rib geometry. When 5052/6061 alloy sheet is cold-stamped in our press dies, the parallel structural ribs work-harden the metal and multiply its section modulus, allowing a thin, rigid alloy skin to pass 40 kg (on 535–660 mm cases) and 60 kg (on 685–835 mm cases) 4-hour static compression tests without the thick wall gauge required by polymer shells. At the case mouth, the extruded 5052/6061 frame tests at ≥ 40 HWB Brinell hardness under ISO 6506 / ASTM E10.
Because metal shells conduct heat and cold rapidly and do not crack under sub-zero brittle transition like standard plastics, the AURA body remains structurally stable from -40 °C to 120 °C. Rather than shattering under a severe ramp impact, a stamped metal body produces a localized dent that preserves cargo integrity and can be pressed back out. Inside, dual removable divider boards and dry-wet separation pockets secure contents; exact lining fabric specification is confirmed per order.
Progressive cold-stamping forms deep structural ribs into 5052/6061 aluminium-magnesium sheet, delivering a 3.7 kg 20-inch metal body stable from -40 °C to 120 °C.
Electrochemical anodising grows a 10–12 μm oxide film verified to ISO 9227 / ASTM B117 (16-hour neutral salt spray, ≤ 3 corrosion points, ≤ 1 mm²).
Overlapping 5052/6061 corner guards riveted onto the metal shell pass 900 mm room-temperature and 90 cm cryogenic (-12 °C, 4 h) steel-plate drop tests.
Four SilentMove 360° dual-spinner wheels support up to 105 L expedition loads across 8+2+2 km drum tests (≤ 2 mm wear) and 25 consecutive 200 mm steps.
Sealed precision bearings isolate metallic resonance from the stamped aluminium shell, keeping rolling sound under 40 dB across stone and tile concourses.
AURA achieves the lowest specific weight ratio (kg/L) in our entire factory across every single size tier. Because a stamped 5052/6061 aluminium sheet requires no bulky internal plastic reinforcing ribs or thick thermoformed corners, the 54.1 × 36.6 × 23.9 cm (20-inch) carry-on yields 45 L of internal volume at just 3.7 kg net weight — a specific ratio of 0.082 kg/L (compared with 0.101 kg/L on Captain Zipperless, 0.104 kg/L on Captain Aluminum Frame, and 0.112 kg/L on Voyager).
At the top of the four-size ladder (20, 24, 26, and 28 Inch), the 28-inch AURA (77.0 × 51.1 × 29.5 cm) reaches 105 L of internal volume — the only suitcase in our Bogor factory to break the 100-litre mark (20 L larger than the 85 L 28-inch Captain Aluminum Frame case, yet 0.6 kg lighter at 5.7 kg vs 6.3 kg). At 5.7 kg for 105 L, the 28-inch AURA achieves an extraordinary 0.054 kg/L specific ratio, leaving travellers 17.3 kg of usable baggage allowance under a standard 23 kg airline economy check-in limit. Note that the metric dimensions below (H × W × D axis order) are × 2.54 metric conversions from the original inch tables:
| Size Step | External Dimensions (H × W × D, cm) | Packed Carton (cm) | Capacity (L) | Net Weight (kg) | Gross Weight (kg) | Specific Ratio (kg/L) |
|---|---|---|---|---|---|---|
| 20 Inch (Carry-On) | 54.1 × 36.6 × 23.9 cm | 39.9 × 25.9 × 59.9 cm | 45 L | 3.7 kg | 4.5 kg | 0.082 kg/L |
| 24 Inch (Medium Checked) | 67.1 × 45.5 × 25.9 cm | 47.0 × 27.4 × 70.1 cm | 65 L | 4.52 kg | 5.8 kg | 0.070 kg/L |
| 26 Inch (Medium-Plus) | 71.1 × 48.0 × 27.9 cm | 49.5 × 28.4 × 74.4 cm | 80 L | 4.9 kg | 6.35 kg | 0.061 kg/L |
| 28 Inch (Large Trunk) | 77.0 × 51.1 × 29.5 cm | 53.6 × 31.0 × 80.5 cm | 105 L | 5.7 kg | 7.15 kg | 0.054 kg/L |
Most full-aluminium luggage factories restrict buyers to raw Silver, Black, and Champagne because dyeing stamped aluminium panels evenly across large 77.0 cm shells requires tight electrolytic bath control. The AURA Collection offers 8 standard colours — the widest colour palette in our factory: Black, White, Blue, Green, Gunmetal Gray, Olive Green, Red, and Silver. This 8-colour range lets private-label brands pair classic executive metals (Silver, Gunmetal Gray, Black) with seasonal hero shades (Olive Green, Red, Blue, Green, White) on the exact same stamped 5052/6061 tooling.
Unlike liquid paint that chips off plastic shells on airport carousels, AURA’s metallic finishes are grown directly out of the 5052/6061 alloy surface via electrochemical anodising to a controlled oxide film thickness of 10–12 μm (with high-adhesion baked finish applied on opaque White). During anodising, microscopic pores in the 10–12 μm aluminium oxide crystal layer absorb the metallic dye before hydrothermal sealing locks the colour in permanently. Under ISO 9227 / ASTM B117 testing, the anodised shell and hardware pass 16 hours of neutral salt spray with ≤ 3 corrosion points and no spot larger than 1 mm², ensuring coastal humidity and sea-freight transit never blister or peel the finish.
Branding a stamped 5052/6061 full-aluminium body requires different engineering from badging a polycarbonate shell. Drilling unsealed holes through an anodised metal skin after bath treatment can expose bare aluminium edges to galvanic corrosion and compromise water resistance. On the AURA Collection, our in-house tooling team stamped a precision flat escutcheon recess into the upper front panel before the 10–12 μm anodising stage, allowing three clean OEM branding methods at our 100-piece per SKU minimum:
Each AURA suitcase ships in an individual protective PE bag, foam corner blocks, and a double-wall corrugated export carton (39.9 × 25.9 × 59.9 cm for 20" up to 53.6 × 31.0 × 80.5 cm for 28") printed with your custom carton marks (carton mark), barcode labels, and hangtags.
With 8 anodised colours and 4 size steps (20, 24, 26, and 28 Inch), the full AURA matrix spans 32 possible colour × size SKUs. At our factory MOQ of 100 pcs per SKU (calculated per colour × size combination), ordering all 32 SKUs at once would require 3,200 full-aluminium suitcases — an unnecessary capital lockup for most brands. Instead, we advise buyers to structure their AURA procurement around three proven merchandising models:
Manufactured in Bogor by PT. DJI Travel Products Indonesia (group luggage manufacturing since 2011 — 14 years; Indonesia plant operating since 2025; 75 staff; 80,000 units/month capacity; ISO 9001 currently in registration), samples ship in 7–15 working days and bulk orders deliver in 25–55 working days with Form D, Form E, RCEP, IJEPA, or ICO certificates of origin.
What is the difference between a full-aluminium suitcase and an aluminium-frame suitcase? A full-aluminium suitcase like the AURA Collection has both its ribbed body shells and its perimeter closure frame stamped and extruded from 5052/6061 aluminium-magnesium alloy — zero plastic in the shell. An aluminium-frame suitcase (such as our Captain or Voyager lines) uses a thermoformed Covestro polycarbonate or ABS+PC plastic shell riveted to a 5052/6061 metal perimeter frame. Full aluminium will not crack at -40 °C and develops a metal patina, while polycarbonate-plus-frame lowers unit material cost.
Why is the 20-inch AURA full-aluminium suitcase (3.7 kg) lighter than your polycarbonate-frame carry-ons (4.04–4.85 kg)? Cold-stamping parallel ribs into 5052/6061 aluminium-magnesium alloy sheet work-hardens the metal and creates high structural rigidity without thick polymer walls or heavy internal reinforcing frames. Combined with an efficient 54.1 × 36.6 × 23.9 cm cavity that holds 45 L, the 20-inch AURA achieves a 0.082 kg/L weight-to-volume ratio — the lightest in our factory.
Can we mix the 8 anodised colours within a single order, and how is the 100-piece MOQ calculated? Yes, you can combine any of the 8 colours (Black, White, Blue, Green, Gunmetal Gray, Olive Green, Red, Silver) in one shipment, provided each individual colour × size SKU meets the 100-piece minimum. For example, ordering 100 units of 20-inch Silver, 100 units of 20-inch Gunmetal Gray, and 100 units of 20-inch Olive Green totals 300 pieces across 3 SKUs.
Will the coloured anodised finish peel or corrode in humid coastal climates? No. Except for baked opaque White, the colour is electrochemically grown into a 10–12 μm anodised aluminium oxide layer rather than painted on top. In laboratory testing under ISO 9227 / ASTM B117, AURA hardware and panels pass 16 hours of neutral salt spray with ≤ 3 corrosion spots and ≤ 1 mm² spot size, and withstand temperatures from -40 °C to 120 °C.
What private-label logo methods work best on the AURA metal shell? We recommend either a CNC-machined metal badge bonded into the stamped front escutcheon recess with 3M structural acrylic tape, fibre-laser engraving directly into the 10–12 μm anodised layer, or a sealed blind-riveted emblem. All three methods require zero new shell tooling at the 100-piece per SKU minimum.
The AURA Collection stands apart from every other suitcase on this site on three hard metrics: shell material, weight-to-volume efficiency, and maximum trunk capacity. AURA is our only full-aluminium (5052/6061) line; the other three collections all pair a Covestro polycarbonate / ABS+PC shell with a 5052/6061 frame. In the 20-inch carry-on size, AURA is the lightest (3.7 kg / 45 L = 0.082 kg/L), beating both the Captain Aluminum Frame Carry-On (4.04 kg / 39 L = 0.104 kg/L) and the Voyager Zipperless Aluminum Frame Carry-On (4.38 kg / 39 L = 0.112 kg/L).
If your target retail price requires a polycarbonate shell rather than full metal, choose among our three frame lines by your merchandising goal: pick Captain Aluminum Frame if you want the same four-step 20/24/26/28 Inch size ladder in 6 colours for nested sets; pick Captain Zipperless if you want maximum 48 L cabin volume in a 20-inch case (4.85 kg, 0.101 kg/L) across a lean 3-colour SKU lineup; or pick Voyager for a classic fine-rib shell in 4 metallic neutrals. Review all categories on our products overview.
Launch your flagship metal luggage line in up to 8 anodised colours and 4 sizes (45 L to 105 L) at 100 pcs per SKU — with 7–15 day sampling and 25–55 day bulk production at PT. DJI Travel Products Indonesia.