Closely Pitched Fine-Rib Shell
Vacuum-thermoformed Covestro polycarbonate with horizontal fine-rib corrugations that boost flexural modulus and hide carousel scuffs from -40 °C to 120 °C.
What separates the Voyager Zipperless from a flat-panel or wide-rib plastic suitcase is the pitch and profile of its horizontal fine-rib (fine-rib) corrugations. In our Bogor plant — where mould making is 100% in-house alongside two 1,500-tonne injection machines — the Voyager cavity is machined with closely spaced horizontal ribs running continuously across the front and rear clamshells. When extruded Covestro polycarbonate (or a buyer-specified ABS+PC sheet blend) is heated and vacuum-thermoformed over this tool, those closely pitched ribs act like miniature I-beams across the face of the suitcase.
From a mechanical standpoint, closely spaced fine ribs distribute localized point impacts across multiple adjacent ridges rather than allowing a flat polymer panel to oil-can or crease inward. Combined with the riveted 5052/6061 aluminium-magnesium alloy perimeter frame (Brinell hardness ≥ 40 HWB per ISO 6506 / ASTM E10) and four riveted 5052/6061 corner guards, the Voyager shell passes 900 mm room-temperature drops (18–25 °C) onto a solid carbon-steel plate, 90 cm cold drops after 4 hours at -12 °C, and 4-hour static compression loads of 40 kg (for 535–660 mm bodies) and 60 kg (for 685–835 mm bodies). From a visual standpoint, fine-rib geometry breaks up specular reflections under retail spotlights and hides horizontal baggage-chute scuffs far better than a smooth high-gloss shell.
The perimeter closure replaces vulnerable zipper tape with dual flush-mounted TSA combination latches that lock directly into the extruded 5052/6061 frame channel. Inside the clamshell, dual full-fabric divider panels and wet-dry pockets keep business attire separated; exact lining fabric weight and internal pocket layout are confirmed per order on your production sheet.
Vacuum-thermoformed Covestro polycarbonate with horizontal fine-rib corrugations that boost flexural modulus and hide carousel scuffs from -40 °C to 120 °C.
Extruded 5052/6061 alloy frame riveted around the shell opening (Brinell hardness ≥ 40 HWB per ISO 6506 / ASTM E10) with 10–12 μm anodised corrosion protection.
Four riveted 5052/6061 alloy corner guards and side bumper studs keep the fine-ribbed shell off wet tarmac and pass 900 mm steel-plate drop testing.
Four dual-wheel SilentMove spinners tested over 8 km + 2 km + 2 km obstacle drums (≤ 2 mm wear) and 25 consecutive 200 mm steps under payload.
Lateral wide-profile telescopic handle maximizes flat packing space while precision wheel bearings keep corridor rolling noise within 40 dB.
If you have reviewed our factory specification tables on /products/, you will recognize the Voyager 20-inch and 24-inch measurements immediately: Voyager is the physical reference case from which our site-wide standard 20-inch and 24-inch dimensions were measured (calipered as complete, ready-to-roll suitcases including SilentMove wheels and telescopic handle). Rather than chasing maximum boxiness like our 48 L Captain Zipperless mould, the 20-inch Voyager (37.6 × 22.6 × 58.4 cm, W × D × H) keeps its depth trim at 22.6 cm and net weight at 4.38 kg for a balanced 39 L cabin capacity (a 0.112 kg/L weight-to-volume ratio) that slides into narrow regional-jet overhead bins.
When stepping up to the 24-inch medium checked size (37.6 × 30.5 × 65.5 cm), our mould keeps the 37.6 cm width constant while expanding the depth from 22.6 cm to 30.5 cm (+7.9 cm). That deeper chamber boosts capacity by 53.8% from 39 L to 60 L while adding only 0.50 kg of net weight (4.88 kg), improving the specific weight ratio to 0.081 kg/L. Like Captain Zipperless, the Voyager line skips the 26-inch step and offers a 28-inch large checked case (external 49.5 × 32 × 68.5 cm, net weight 5.2 kg); exact 28-inch litre volume, carton dimensions, and gross weight are confirmed per order prior to shipment.
| Size Step | Overall Dimensions (W × D × H, cm) | Measurement Basis | Capacity (L) | Net Weight (kg) | Specific Ratio (kg/L) |
|---|---|---|---|---|---|
| 20 Inch (Carry-On) | 37.6 × 22.6 × 58.4 cm | Includes wheels & handle | 39 L | 4.38 kg | 0.112 kg/L |
| 24 Inch (Medium Checked) | 37.6 × 30.5 × 65.5 cm | Includes wheels & handle | 60 L | 4.88 kg | 0.081 kg/L |
| 28 Inch (Large Checked) | 49.5 × 32 × 68.5 cm | External shell & frame | Confirmed per order | 5.2 kg | Confirmed per order |
Bright pastel suitcases attract window shoppers, but corporate travel programs, airline crew stores, and executive luggage brands generate 80%+ of their repeat volume from dark and metallic neutrals. The Voyager line is curated around four disciplined shades: Black, Black Silver, Grey, and Silver. Every colourway uses the exact same fine-rib Covestro polycarbonate / ABS+PC shell mould and 5052/6061 alloy frame, but changes the visual relationship between shell pigment and anodised metal hardware.
The standout SKU in this four-colour matrix is Black Silver. Instead of a gradient paint job, Black Silver is a deliberate two-tone component assembly: we pair the matte-textured Black fine-rib polycarbonate shell with raw natural-silver anodised 5052/6061 perimeter frames, silver riveted corner guards, and silver latch trim. That high-contrast metallic outline gives brands the visual look of an exposed metal-frame trunk against a dark body, whereas the standard Black colourway uses black-anodised frame and corner hardware for a stealth monochrome finish. Across all four options, the 10–12 μm anodised oxide film passes 16-hour ISO 9227 / ASTM B117 neutral salt-spray testing (≤ 3 corrosion points, ≤ 1 mm²) and -40 °C to 120 °C thermal cycling.
Because the Voyager line already includes a two-tone contrast build (Black Silver) alongside monochrome Black, Grey, and Silver as standard factory colourways, private-label buyers can create a distinctive executive collection at the 100-piece per SKU minimum without paying custom masterbatch dyeing fees or custom anodising bath setup charges.
To turn the baseline Voyager mould into your proprietary brand line at our Bogor facility, we configure five factory-installed details:
When first-time OEM and ODM buyers visit or audit PT. DJI Travel Products Indonesia in Bogor (Jl. Raya Parung, Kemang, Kab. Bogor 16310; 75 staff; 80,000 units/month capacity; group luggage manufacturing since 2011 — 14 years — and Indonesia plant producing since 2025), the Voyager 20-inch carry-on is the benchmark sample we put on the table first. Because its 37.6 × 22.6 × 58.4 cm (4.38 kg, 39 L) and 37.6 × 30.5 × 65.5 cm (4.88 kg, 60 L) proportions represent our baseline engineering standard, evaluating a Voyager sample gives you an immediate physical reference for our Covestro PC sheet rigidity, 5052/6061 frame riveting tolerances, and SilentMove wheel acoustics.
At an MOQ of 100 pcs per colour × size SKU, here is how mid-to-high-tier brands structure their opening Voyager order:
Pre-production samples ship in 7–15 working days, and bulk orders complete in 25–55 working days after deposit and sample approval (ISO 9001 quality management system currently in registration; IQC, IPQC, and final OQC/AQL inspections applied to every lot).
How does a fine-rib polycarbonate shell perform differently from a smooth or wide-rib shell? Closely pitched horizontal fine ribs increase the flexural stiffness of the thermoformed Covestro polycarbonate / ABS+PC sheet without adding wall weight, helping the 20-inch (4.38 kg) and 24-inch (4.88 kg) cases resist inward buckling under 40–60 kg 4-hour static load tests. Visually, fine ribs break up glare and conceal conveyor-belt abrasion marks much better than flat glossy shells.
What does the Black Silver colourway mean — is it a two-colour shell or a gradient? Neither. Black Silver is a two-tone component build: it pairs a solid matte Black fine-rib polycarbonate shell with natural silver-anodised 5052/6061 aluminium perimeter frames, silver riveted corner guards, and silver latch trim. If you prefer all-black hardware on a black shell, choose the standard Black colourway.
Do the 37.6 × 22.6 × 58.4 cm (20") and 37.6 × 30.5 × 65.5 cm (24") dimensions include the wheels and handle? Yes. Voyager is the physical benchmark model for our site-wide 20-inch and 24-inch dimension tables: both 37.6 × 22.6 × 58.4 cm (20", 39 L, 4.38 kg) and 37.6 × 30.5 × 65.5 cm (24", 60 L, 4.88 kg) are measured as complete, overall dimensions including the SilentMove spinner wheels and recessed telescopic handle.
Is the 28-inch Voyager checked case built with the same fine-rib design, and what are its specs? Yes, the 28-inch large checked case continues the fine-rib shell architecture with external dimensions of 49.5 × 32 × 68.5 cm and a net weight of 5.2 kg (no 26-inch step is produced on this mould). Exact 28-inch internal litre capacity, export carton dimensions, and gross shipping weight are confirmed per order on your quotation.
Can the riveted 5052/6061 aluminium frame loosen after repeated airline baggage drops? No. Our Bogor assembly line rivets the Covestro PC shell to an extruded 5052/6061 alloy frame rated ≥ 40 HWB Brinell hardness (ISO 6506 / ASTM E10) and reinforces all four corners with riveted alloy guards. Completed cases must pass 900 mm room-temperature drops onto solid carbon steel and 90 cm cold drops (-12 °C for 4 hours) without rivet shear or frame separation.
Buyers frequently compare the Voyager with our Captain Zipperless Aluminum Frame Carry-On because both use a Covestro polycarbonate / ABS+PC shell riveted to a zipperless 5052/6061 alloy frame across 20 / 24 / 28 Inch sizes. The difference starts at the mould: Voyager is formed on a slimmer fine-rib cavity (37.6 × 22.6 × 58.4 cm in 20", 4.38 kg, 39 L, 0.112 kg/L; 37.6 × 30.5 × 65.5 cm in 24", 4.88 kg, 60 L) and offers 4 metallic neutrals including two-tone Black Silver. Captain Zipperless uses a wider, deeper mould (38 × 23 × 54 cm in 20", 4.85 kg, 48 L, 0.101 kg/L; 42.5 × 26 × 64 cm in 24", 5.3 kg, 66 L) across 3 colours (Black, Grey, Silver) for buyers prioritizing maximum litre volume per case.
If your program requires a 4-size nested retail set (20 / 24 / 26 / 28 Inch) with the scarce 73 L 26-inch Medium-Plus size and 6 colours (adding Blue, Green, Pink, and White), choose the Captain Aluminum Frame Carry-On. And if you want a stamped 5052/6061 full-metal body rather than a polycarbonate shell, step up to the AURA Collection (3.7 kg / 45 L in 20" up to 105 L in 28", 8 anodised colours). Compare all four lines on our full product directory.
Order a 20-inch or 24-inch Voyager sample in Black, Black Silver, Grey, or Silver (7–15 working days) or book a 100-piece per SKU production run with 25–55 day delivery from PT. DJI Travel Products Indonesia.