An ABS suitcase shell is a vacuum formed half-shell judged by a drop test and by how it looks after ten flights, and both of those come back to draw ratio and surface texture.
A luggage brand in Guangzhou formed cabin shells from 1.5 mm ABS with a 12 mm corner radius. Drop tests at 1 m produced cracks at the base corners on 6 percent of samples, and the tool was rebuilt with 35 mm radii.
ABS suitcase shell gauge and draw
- Cabin shell: 1.5 to 2 mm
- Checked shell: 2 to 2.5 mm
- Corner radius: 30 to 40 mm
- Draw ratio: 1.2 to 1 maximum
The corner is where a formed shell either passes or fails. Material stretches as it is drawn into the corner, and a tight radius takes the stretch out of a small area; a generous radius spreads it over a wider band and keeps the wall.
Texture, hardware and the blend option
Texture is a durability decision dressed as a styling one. A fine matte grain scatters light and hides the scratches from belts and overhead bins; gloss shows every mark and the shell looks tired after one season.
An ABS and polycarbonate blend is the upgrade for a shell that must survive airport handling. The blend keeps the forming behaviour of ABS and adds the low-temperature impact resistance that prevents shattering in a cold hold.
For the forming parameters behind this, see ABS vacuum forming.
Send your shell dimensions, target weight and drop test standard to oversales@rpplexiglass.com for a forming quotation.
Frequently Asked Questions
What thickness ABS for a suitcase shell?
1.5 to 2 mm for cabin luggage, 2 to 2.5 mm for checked baggage. Wall thickness at the corners after forming is the real specification, not the flat sheet gauge.
Why do shells crack at the corner?
Thinning during the draw plus a tight radius. A 40 mm corner radius on a 2 mm shell keeps 70 percent of the wall; a 10 mm radius drops it to half and the corner fails on the first drop.
Does texture matter on a shell?
Yes, functionally. A fine grain hides the scratches every airport belt puts on a shell; a gloss finish shows every scuff and reads as a used case after one trip.