Squared 48 L Covestro PC Cavity
Thermoformed from Covestro polycarbonate or ABS+PC sheet on a dedicated 38 × 23 × 54 cm cabin mould, holding dimensional stability from -40 °C to 120 °C without brittle cracking.
Most buyers comparing zipperless carry-ons assume that every 20-inch polycarbonate frame case comes out of the same shell cavity with different surface ribs. In our Bogor factory (equipped with two 1,500-tonne injection machines and 100% in-house mould making), the Captain Zipperless line runs on an independent shell tool that is geometrically distinct from the Voyager line. While the Voyager 20-inch mould tapers to 37.6 × 22.6 × 58.4 cm for a slender 39 L silhouette, the Captain Zipperless 20-inch cavity widens the body to 38 cm, pushes the depth to 23 cm, and squares the corner radii at a 54 cm overall height. Those millimetre shifts across the crown and sidewalls yield 48 L of usable internal volume in a 20-inch carry-on and 66 L in the 24-inch medium case (42.5 × 26 × 64 cm).
Because a 48 L cabin case carries denser loads than a 39 L case, the shell-to-frame interface has to resist higher torsional twist when lifted by one handle. We form the clamshell halves from Covestro polycarbonate (or a buyer-specified ABS+PC ratio for promotional price tiers) and rivet them to an extruded 5052/6061 aluminium-magnesium alloy perimeter frame. Under ISO 6506 / ASTM E10 testing, the frame mouth maintains a Brinell hardness of ≥ 40 HWB, preventing the clam halves from scissoring out of alignment when dropped from 900 mm at 18–25 °C or from 90 cm after 4 hours of cold conditioning at -12 °C.
Eliminating the perimeter zipper removes the number-one warranty failure point in commercial travel goods: burst coil teeth and torn stitch tape on overpacked bags. Instead of a zipper slider, the Captain Zipperless uses dual mechanical TSA-approved combination latches mounted flush into the 5052/6061 frame channel, paired with an elastomeric perimeter seal that blocks dust and runway rain splash. Inside, dual compression dividers and dry-wet separation pockets keep the 48 L cavity organized; exact lining fabric denier and foam backing weight are confirmed per order on your production tech pack.
Thermoformed from Covestro polycarbonate or ABS+PC sheet on a dedicated 38 × 23 × 54 cm cabin mould, holding dimensional stability from -40 °C to 120 °C without brittle cracking.
Extruded 5052/6061 aluminium-magnesium alloy closure channel rated ≥ 40 HWB Brinell hardness (ISO 6506 / ASTM E10), replacing stitch-sewn zipper coils with dual mechanical drawbolts.
Four riveted 5052/6061 alloy corner guards shield the squared shell vertices through 900 mm room-temperature drops (18–25 °C) and 90 cm cold drops (-12 °C for 4 hours).
Four dual-wheel SilentMove 360° spinners carry 40–60 kg static loads and complete 8 km + 2 km + 2 km drum runs with tread wear held to ≤ 2 mm.
Precision bearing axles and shock-absorbing wheel skins survive 25 consecutive 200 mm step drops under full payload while keeping terminal rolling acoustics below 40 dB.
In hard-shell luggage manufacturing, internal litre volume is governed by three mould parameters: corner radius curvature, wheel-housing recess depth, and frame-channel step height. On the Captain Zipperless 20-inch tool (38 × 23 × 54 cm including wheels), our mould engineers minimized the recessed wheel-well intrusion and pushed the shell walls outward toward the perimeter of the 42 × 28 × 60 cm export carton. The result is a 48 L cabin interior at a net weight of 4.85 kg, yielding a weight-to-volume ratio of 0.101 kg/L. Compared with our Voyager 20-inch carry-on (39 L at 4.38 kg, or 0.112 kg/L), the Captain Zipperless adds 0.47 kg of structural material to gain 9 L of packing volume — improving volumetric efficiency by 9.8% per litre stored.
Stepping up to the 24-inch medium checked case (42.5 × 26 × 64 cm), volume expands by 37.5% to 66 L while net weight rises by only 0.45 kg to 5.3 kg, dropping the specific weight ratio to 0.080 kg/L. The line skips the 26-inch step entirely and moves directly to the 28-inch large checked case (external dimensions 49.5 × 32 × 68.5 cm, net weight 5.2 kg). Please note that the 28-inch size is currently completing final packing specification sign-off; its exact litre capacity, master carton dimensions, and gross shipping weight are confirmed per order at quotation stage. Static load testing across the size range applies 40 kg for 4 continuous hours on 535–660 mm cases (20" and 24") and 60 kg for 4 hours on 685–835 mm cases (28").
| Size Step | External Dimensions (W × D × H, cm) | Packed Carton (cm) | Capacity (L) | Net Weight (kg) | Gross Weight (kg) | Specific Ratio (kg/L) |
|---|---|---|---|---|---|---|
| 20 Inch (Carry-On) | 38 × 23 × 54 cm | 42 × 28 × 60 cm | 48 L | 4.85 kg | 6.1 kg | 0.101 kg/L |
| 24 Inch (Medium Checked) | 42.5 × 26 × 64 cm | 48 × 33 × 70 cm | 66 L | 5.3 kg | 6.55 kg | 0.080 kg/L |
| 28 Inch (Large Checked) | 49.5 × 32 × 68.5 cm | Confirmed per order | Confirmed per order | 5.2 kg | Confirmed per order | Confirmed per order |
Every additional colourway in a hard-shell luggage line multiplies safety stock, minimum order commitments, and slow-moving warehouse tail inventory. Where our AURA Collection spans 8 colours and the Captain Aluminum Frame line offers 6 colours for decorative retail sets, the Captain Zipperless line is deliberately restricted to three commercial shades: Black, Grey, and Silver. In B2B distribution across China, Indonesia, the United States, Germany, Australia, and the United Kingdom, these three neutral dark-and-metallic tones consistently account for the majority of single-case business travel orders.
Surface durability across all three colourways is engineered for high-frequency transit. The Covestro polycarbonate (or ABS+PC) shell sheets are co-extruded with a matte micro-textured top layer that diffuses overhead airport lighting and masks conveyor-belt abrasion marks on Black, Grey, and Silver bodies alike. The 5052/6061 aluminium-magnesium alloy perimeter frame and four riveted corner guards receive an electrochemical anodised oxide coating controlled to 10–12 μm thickness. In laboratory verification under ISO 9227 / ASTM B117, this anodised hardware endures 16 hours of neutral salt-spray exposure with ≤ 3 corrosion points and no single spot exceeding 1 mm², while the complete shell-and-frame assembly remains dimensionally stable across extreme storage temperatures from -40 °C to 120 °C.
Because PT. DJI Travel Products Indonesia owns the Captain Zipperless shell moulds 100% in-house at our Bogor plant, private-label buyers can deploy full OEM branding at the standard 100-piece MOQ without amortizing shell cavity modifications. The front upper crown of the 38 × 23 × 54 cm (20") and 42.5 × 26 × 64 cm (24") shells features a flat, rib-free badge recess designed to accept stamped metal nameplates, domed epoxy emblems, or high-adhesion silkscreen printing (sablon).
For corporate and retail brands seeking hardware-level differentiation across the Black, Grey, and Silver shells, we offer five zero-tooling customization points:
Our factory MOQ is 100 pcs per SKU, calculated strictly per colour × size combination across both OEM and ODM programs. On an 8-colour, 4-size collection (32 possible SKUs), covering the full matrix requires 3,200 units. By contrast, the Captain Zipperless line is structured for lean inventory velocity: ordering all 3 colours (Black, Grey, Silver) in the flagship 20-inch 48 L carry-on requires just 300 pieces total (3 SKUs × 100 pcs). If you add the 24-inch 66 L medium checked case in Black and Silver, your entire two-size, multi-colour program launches at 500 pieces.
This SKU discipline makes the Captain Zipperless our primary recommendation for three buyer profiles:
From our Bogor facility (75 staff, 80,000 units/month capacity, 100+ containers exported annually; group manufacturing luggage since 2011 — 14 years — and Indonesia factory operating since 2025), custom pre-production samples ship in 7–15 working days. Mass production takes 25–55 working days after deposit and approved sample sign-off (or approximately 80 days total if your project requires a brand-new custom shell mould: 10 days tooling + 25 days mould transit + 45 days production). Export shipments include Indonesian Certificate of Origin (COO / SKA Form D, Form E, RCEP, IJEPA, or ICO), with payment terms, tiered volume pricing, and Incoterms (EXW, FOB Jakarta, or DDP) confirmed per order.
Is a zipperless aluminum-frame suitcase more durable than a zippered case? In commercial luggage returns, perimeter zipper tape and coil teeth are frequent failure points when bags are overpacked or snagged on airport chutes. By replacing the perimeter zipper with an extruded 5052/6061 aluminium-magnesium frame rated ≥ 40 HWB Brinell hardness (ISO 6506 / ASTM E10) and dual mechanical latches, the Captain Zipperless eliminates stitch-line tearing and passes 900 mm room-temperature and 90 cm cold (-12 °C, 4 h) drop tests.
How does the 20-inch Captain Zipperless reach 48 L when other 20-inch cases hold 39 L? The Captain Zipperless is formed on its own dedicated mould measuring 38 × 23 × 54 cm (including wheels), rather than sharing the narrower 37.6 × 22.6 × 58.4 cm Voyager cavity. The wider 38 cm stance, fuller 23 cm depth, and squared corner geometry create 48 L of interior volume at 4.85 kg net weight (0.101 kg/L).
How do the dual TSA latches work, and can customs officers open them without damage? Instead of a sliding zipper puller, two spring-loaded mechanical latches clamp directly into the 5052/6061 aluminium perimeter frame. Each latch integrates a 3-dial combination lock with a standard keyhole slot, allowing customs inspectors to unlock, inspect, and relock the case using an official master key without prying the frame.
Why are only 3 colours listed, and can we order a custom Pantone shell colour? We stock Black, Grey, and Silver as standard options so buyers can launch all three shades in the 20-inch size with just 300 pieces (100 pcs per colour × size SKU). Custom Pantone polycarbonate extrusion or custom frame anodising colours can be produced for OEM orders; colour matching and minimum sheet tonnage are confirmed per order.
Both Captain Zipperless and Voyager are zipperless aluminum-frame cases — how should a buyer choose between them? Choose by mould geometry, capacity, and colour count: Captain Zipperless uses a wider 38 × 23 × 54 cm mould that holds 48 L in the 20-inch size (4.85 kg) and 66 L in the 24-inch size (5.3 kg) across 3 colours (Black, Grey, Silver). Voyager uses a slender fine-rib mould (37.6 × 22.6 × 58.4 cm) holding 39 L in 20-inch (4.38 kg) and 60 L in 24-inch (4.88 kg) across 4 metallic colours including two-tone Black Silver.
Although both belong to our zipperless polycarbonate-plus-frame category, the Captain Zipperless and the Voyager Zipperless Aluminum Frame Carry-On do not share shell moulds. Captain Zipperless prioritizes maximum cabin volume (48 L in 20-inch at 4.85 kg, 0.101 kg/L; 66 L in 24-inch at 5.3 kg) and SKU simplicity (3 colours: Black, Grey, Silver). Voyager prioritizes a slimmer fine-rib profile (39 L in 20-inch at 4.38 kg, 0.112 kg/L; 60 L in 24-inch at 4.88 kg) and adds a fourth two-tone Black Silver finish.
If your merchandising plan requires a 4-piece nested retail set that includes the rare 26-inch Medium-Plus size and 6 colourways with stamped corner caps, move to the Captain Aluminum Frame Carry-On (20/24/26/28 inch, 39–85 L). If your brand is positioning a true full-metal flagship rather than a polycarbonate shell on an alloy frame, select the AURA Collection — our only stamped 5052/6061 full-aluminium line (3.7 kg / 45 L in 20-inch, scaling to 105 L in 28-inch across 8 anodised colours). View all specifications side by side on our complete luggage catalogue.
Specify the Captain Zipperless when your brief calls for 48 L cabin capacity, a riveted 5052/6061 frame, and a 3-colour SKU structure produced at 100 units per colour-size in 25–55 working days.