Custom Luggage Manufacturing
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Your specification on a structure we already make - colours, hardware, lining, branding and carton marks - without the cost and lead time of a new steel mould.
Your specification on a structure we already make - colours, hardware, lining, branding and carton marks - without the cost and lead time of a new steel mould.
Custom luggage manufacturing at PT. DJI Travel Products Indonesia means your specification built on a structure that already runs in production: your shell colour, your hardware, your lining, your branding, your carton marks. You do not pay for a new steel cavity, and you do not wait for one.
This is the route most brands should start with, and it is the one that gets confused with OEM most often. A custom luggage manufacturer working from existing moulds changes what sits inside and outside a proven case — colour, finish, wheels, zippers, locks, interior, logo, packaging. An OEM programme cuts a new cavity because the shell geometry itself is yours. If your drawings already exist and the shape must be yours alone, read the OEM page instead; if you are choosing from our own range with light changes, ODM and private label describe the smaller steps. Everything below is the middle ground: a real specification, without tooling.
Because the cavity is shared, the commercial difference is large. MOQ stays at 100 pcs per SKU, sampling runs 7 to 15 working days, and bulk production is 25 to 55 working days from deposit and approved sample — against roughly 80 days before a new OEM mould has even finished its mass-production run.
Build the specification from these layers. Each one is confirmed on the proforma invoice before sampling, not after.
Three things do not change on a custom programme, and all three are what remove the tooling bill. The shell cavity is one we already run. The body size belongs to an existing size family — 20", 24" and 28" on the Voyager and Captain lines, 26" in the AURA and Captain families. And the structural test baseline is the one the platform already passes, so there is no new validation cycle to fund.
A new body dimension cannot grow out of an existing cavity: draft angle and volume change with the dimensions, so a new size is a new mould. That is an OEM programme, quoted separately, at roughly 80 days. Being clear about this before quoting saves both sides a wasted cycle.
The other fixed element is the factory itself. Hard-shell lines run in Bogor — four production lines across 10,000 m², 75 staff, 80,000 units a month, mould making 100% in-house. Fabric and soft-shell work is handled at our group base in China, so a mixed hard-shell and soft-shell order is quoted as two production streams. The group has been manufacturing luggage since 2011; this Indonesia plant has been producing since 2025.
Material choice drives both the price and the market. Virgin Covestro PC gives the best impact performance and the cleanest gloss, which is why the aluminium-frame lines use it under a 5052/6061 frame. ABS and ABS+PC bring the unit cost down while keeping a hard-shell feel; the PC fraction is specified rather than implied, and the exact blend is written into the bill of materials for your SKU.
On the aluminium lines the anodised film is held at 10–12 μm. That thickness is what carries the colour and resists oxidation, and it is measured rather than judged by eye. Shell and frame finish are approved on the same strike-off sample, so the two read as one product in daylight rather than only in a photograph.
Every component is expected to operate across −40 °C to 120 °C. For a UK or Australian programme that envelope is wider than the market needs, which is the point: the specification should not be the thing that fails when a container sits on a wharf in February.
Branding is applied at the stage where it is most durable for the volume. Metal badges and embossing sit on the shell; silk print and custom zipper pulls work where a lower unit cost matters more than permanence; printed lining and hangtags carry the brand story inside the case.
Export preparation is part of the programme rather than an afterthought: carton marks, packing list and the shipping documents your forwarder needs. Cases are packed to survive the container, and packaging is confirmed against the destination market's rules per order. If you sell in the EU, that conversation happens before the first carton is printed, not at the port.
The minimum order is 100 pcs per SKU, counted by size and colour combination — so a two-colour, two-size programme is four SKUs and four minimums. Payment terms are 30% deposit and 70% balance, the same on custom, ODM and OEM orders.
Sampling takes 7 to 15 working days and is where colour, hardware and branding are approved in the hand. Bulk production then runs 25 to 55 working days from deposit and approved sample, with capacity of 80,000 units a month behind it. Shipping more than 100 forty-foot high-cube containers a year to China, Indonesia, the United States, Germany, Australia and the United Kingdom means the schedule is a factory schedule, not a trading company's estimate.
Because the platform is shared, the test baseline is already established — and it is the same protocol every programme runs, whether the case carries our structure or your branding.
These are enforced through IQC, IPQC and OQC inspection stages. ISO 9001 is in registration, and SGS produces sample test reports on submitted samples — documented evidence for the specific case you order, rather than a certificate describing a category.
Most UK and Australian brands we quote sit between 100 and a few hundred pieces per SKU. That volume cannot absorb a steel mould, and it does not need to: a custom programme delivers your colours, hardware and branding at 100 pcs per SKU, which is exactly why this route exists alongside OEM.
Both markets also care about the same practical details — carton marks that match the retailer's routing guide, packaging that satisfies the destination rules, and a lead time that survives a sea freight schedule. The United Kingdom and Australia are already among the six markets we ship to, alongside China, Indonesia, the United States and Germany.
What is the minimum order for custom luggage? 100 pcs per SKU, counted by size and colour combination. A 20" and a 24" in two colours is four SKUs, so four minimums.
Can you make a size that is not in your range? A new body dimension needs its own steel cavity, because draft angle and volume change with the dimensions. That is an OEM tooling programme of roughly 80 days. From the existing families we run 20", 24" and 28" on the Voyager and Captain lines, and 26" in the AURA and Captain families.
We only want our logo on an existing case — is that custom? That is private label, the smallest step. Custom starts when colour, hardware, lining or packaging also changes. All of them run out of the same plant, and a programme can move up between them as volume grows.
How long from approved sample to delivery? 25 to 55 working days of production from deposit and approved sample, plus transit. Sampling itself takes 7 to 15 working days.
Do you charge for samples? Samples are produced in 7 to 15 working days; the sample and courier cost is confirmed per order and depends on what has to be made for the approval.
Can we see test reports before ordering? Yes. SGS produces sample test reports on submitted samples, and the internal protocol behind them is the drop, compression, wheel, salt-spray and hardness sequence listed above.
Can hard-shell and soft-shell items sit in one order? Hard-shell production runs in Bogor; fabric and soft-shell work is produced at our group base in China. A mixed order is quoted as two production streams with their own lead times.
