How to Choose Carry-On Luggage 2026
Traveling light doesn’t mean traveling poorly—especially when you’re armed with the right carry-on luggage. In today’s fast-paced world of air travel, where every minute and inch counts, choosing the perfect expandable rolling carry-on can make or break your journey. Whether you’re a frequent flyer logging 100,000 miles a year or a weekend warrior escaping for a quick city break, your luggage is more than just a bag—it’s your mobile command center, your wardrobe, and sometimes your only storage for days. With airlines tightening size restrictions, charging for checked bags, and increasing scrutiny at the gate, having a reliable, well-designed carry-on has never been more important.
This comprehensive buying guide is designed to cut through the noise and help you make a smart, informed decision. We’ll walk you through everything you need to know—from understanding airline size limits and evaluating build quality to comparing materials, features, and price points. You’ll learn how to spot a durable suitcase that won’t crack under pressure, how to maximize packing efficiency with smart organizational features, and how to avoid common pitfalls that lead to buyer’s remorse. By the end, you’ll have a clear roadmap to selecting the ideal expandable rolling carry-on that fits your travel style, budget, and long-term needs.
The market for carry-on luggage has exploded in recent years, with dozens of brands—from legacy names like Samsonite and Travelpro to innovative newcomers like Away and Monos—offering a dizzying array of options. Expandable models, in particular, have gained popularity because they offer flexibility: pack light for a short trip, then expand when you need extra space for souvenirs or unexpected purchases. But not all expandable suitcases are created equal. Some sacrifice durability for extra inches, while others add so many features that they become unwieldy. This guide will help you navigate the choices, weigh the trade-offs, and find the perfect balance of form, function, and value.
What to Look for When Buying Buying Guide
1. Size & Airline Compliance
The single most important factor when choosing a carry-on is ensuring it meets airline size requirements. Most major U.S. and international airlines allow carry-on bags up to 22 x 14 x 9 inches (including wheels and handles), but some—like Delta, United, and American—have slightly different limits, and low-cost carriers like Spirit and Frontier are notoriously strict. Always check your airline’s specific guidelines before purchasing.
Expandable suitcases add complexity because the expanded dimensions may exceed carry-on limits. For example, a bag that’s 22” tall when closed might grow to 24” when expanded—making it too large to fit in overhead bins. Look for models that expand vertically or horizontally without pushing past the 22-inch threshold. Some brands, like Briggs & Riley and Tumi, design their expandable zippers to add only 1–2 inches, keeping the bag compliant even when fully expanded.
Also consider the internal capacity. A standard 22-inch carry-on typically holds 35–45 liters. Expandable versions can add 5–10 liters, which is perfect for a 5–7 day trip. But be cautious: overpacking an expandable bag can make it difficult to maneuver and increase the risk of damage to the zipper or frame.
2. Build Quality & Durability
Durability is non-negotiable when it comes to luggage. A suitcase that cracks, breaks, or fails after a few trips is not just inconvenient—it’s a waste of money. The best carry-ons are built to withstand the rigors of airport handling, overhead bin storage, and frequent use.
Start with the shell material. Hard-shell suitcases are typically made from polycarbonate, ABS, or aluminum. Polycarbonate is the gold standard—lightweight, flexible, and highly impact-resistant. It can absorb shocks without cracking, making it ideal for frequent travelers. ABS is cheaper but less durable and prone to cracking under pressure. Aluminum offers premium protection and a sleek look but is heavier and can dent easily.
Soft-shell suitcases, usually made from ballistic nylon or polyester, are lighter and more flexible. They’re great for squeezing into tight spaces and often include external pockets for quick access. However, they offer less protection for fragile items and may wear faster over time.
Pay attention to the frame and corners. Reinforced corners with protective bumpers (like those found on the Rimowa Essential or the Samsonite Winfield 3) help absorb impact during rough handling. A sturdy internal frame or compression system adds structural integrity and prevents the bag from collapsing when overloaded.
Finally, inspect the zippers. YKK zippers are industry-standard for reliability. Avoid bags with flimsy, plastic zippers that can jam or break. Expandable zippers should be smooth, double-stitched, and reinforced with fabric tape to prevent tearing.
3. Wheel System & Maneuverability
Wheels are the unsung heroes of carry-on luggage. A smooth, responsive wheel system can make navigating crowded terminals, cobblestone streets, and airport escalators a breeze—while a poor one can turn a short walk into a frustrating ordeal.
Look for 360-degree spinner wheels (four wheels that rotate independently). These allow you to glide the bag in any direction with minimal effort, making tight turns and crowded spaces manageable. Dual-wheel (two-wheel) models are more traditional and offer better stability on uneven terrain, but they require more effort to maneuver and can’t pivot as easily.
The quality of the wheels matters just as much as the number. High-end suitcases use polyurethane or rubberized wheels that are quiet, durable, and resistant to wear. Cheaper models often use hard plastic wheels that can crack, wobble, or make noise on tile floors. Test the wheels by rolling the bag on a flat surface—it should move smoothly without veering to one side.
Also consider the wheel housing. Some bags have exposed wheels that can snag on carpet or get caught in escalator gaps. Others have recessed or protected wheel wells that reduce the risk of damage. The height of the wheels also affects clearance—taller wheels provide better ground clearance on uneven surfaces.
4. Handle Design & Ergonomics
The telescoping handle is your primary point of contact with the bag, so it needs to be comfortable, sturdy, and easy to use. A poorly designed handle can cause hand fatigue, wrist strain, or even injury over long distances.
Look for a handle made from aluminum or reinforced composite materials. It should extend smoothly to at least waist height and lock securely in place at multiple positions. A dual-handle system (one on the top and one on the side) adds versatility—use the top handle for lifting into overhead bins and the side handle for pulling when the bag is lying flat.
The grip should be padded and ergonomically shaped to fit comfortably in your hand. Some premium models, like the Travelpro Platinum Elite, feature contoured grips with textured surfaces to prevent slipping. Avoid handles with sharp edges or thin plastic grips that can dig into your palm.
Test the handle’s stability by extending it fully and applying pressure. It shouldn’t wobble, rattle, or feel loose. A well-built handle will remain rigid even when the bag is fully loaded and pulled over rough terrain.
Also consider the handle’s retraction mechanism. Some bags use a single-button release, while others have a two-stage system for finer control. A smooth, quiet retraction is a sign of quality engineering.
5. Expandability & Packing Efficiency
Expandable carry-ons offer a major advantage: flexibility. But not all expansion systems are created equal. The best ones add usable space without compromising structure or compliance.
Most expandable bags use a zipper system that adds 1–2 inches of depth. Look for a zipper that runs the full width of the bag and is reinforced with fabric tape. Some models, like the Away Carry-On, use a hidden expansion panel that unfolds when needed. Others, like the Monos Carry-On, have a simple side zipper that adds a few extra inches.
When expanded, the bag should still feel balanced and easy to roll. Avoid models that become top-heavy or unstable when expanded—this can make them difficult to maneuver and increase the risk of tipping.
Internal organization is just as important. Look for features like compression straps, zippered dividers, and mesh pockets. These help keep clothes neat, reduce wrinkles, and maximize space. Some bags include removable laundry bags or shoe compartments, which are great for longer trips.
Consider how you pack. If you’re a “roll your clothes” traveler, you’ll benefit from a bag with deep compartments and compression straps. If you prefer folding, look for a suitcase with a flat packing surface and sturdy dividers.
6. Security Features
Your luggage is only as secure as its weakest lock. While carry-ons aren’t typically locked during flight (TSA regulations require bags to be accessible for inspection), having reliable security features gives you peace of mind during layovers, hotel stays, and ground transport.
Look for TSA-approved locks. These allow TSA agents to open and relock your bag using a master key, preventing damage during inspections. Most modern suitcases come with built-in TSA locks, but you can also add external ones if needed.
Some high-end models include additional security features like RFID-blocking pockets (to protect credit cards and passports), hidden zippers, or slash-resistant fabric. While not essential, these can be valuable for international travel or high-risk destinations.
Avoid bags with flimsy latches or zippers that can be easily forced open. A strong, well-designed closure system deters casual theft and keeps your belongings safe.
7. Weight & Portability
Every ounce counts when you’re traveling light. A heavy suitcase reduces your usable packing capacity and increases the risk of exceeding airline weight limits—even for carry-ons.
The ideal carry-on should weigh between 6 and 8 pounds when empty. Premium polycarbonate models, like the Rimowa Essential Lite, can weigh as little as 5.5 pounds, while aluminum or heavily reinforced bags may tip the scales at 9–10 pounds.
Lightweight doesn’t mean flimsy. The best bags use advanced materials and engineering to minimize weight without sacrificing strength. For example, the Samsonite Lite-Shock uses a honeycomb structure to reduce weight while maintaining rigidity.
Also consider the bag’s balance. A well-designed suitcase should feel balanced when pulled, with the weight distributed evenly between the wheels and handle. An unbalanced bag can cause strain and make it harder to control.
8. Brand Reputation & Warranty
Not all luggage brands are created equal. Some have decades of experience and a proven track record of quality, while others are new to the market and untested.
Established brands like Samsonite, Travelpro, and Briggs & Riley are known for their durability, innovation, and customer service. They often offer comprehensive warranties—some even cover damage from airline handling. For example, Briggs & Riley offers a “Simple As That” lifetime warranty that covers any damage, no questions asked.
Newer brands like Away, Monos, and July have disrupted the market with sleek designs, direct-to-consumer pricing, and strong social media presence. While their products are often high-quality, their warranties may be shorter or less comprehensive.
Read customer reviews and check independent testing sites like Wirecutter or Consumer Reports. Look for patterns in feedback—consistent complaints about zippers, wheels, or handles are red flags.
Finally, consider the warranty. A good warranty should cover defects in materials and workmanship for at least 5–10 years. Some brands offer repair services or replacement parts, which can extend the life of your bag.
Different Types of Buying Guide
Common Buying Mistakes to Avoid
❌ Mistake: Ignoring Airline Size Restrictions
Why it’s bad: Buying a bag that’s too large—even by an inch—can result in being forced to check it at the gate, incurring fees and delays. Many travelers assume “carry-on size” is universal, but airlines vary.
What to do instead: Always check your airline’s official carry-on dimensions before purchasing. Use a measuring tape to verify the bag’s total dimensions (including wheels and handles). When in doubt, go smaller.
❌ Mistake: Prioritizing Looks Over Function
Why it’s bad: A suitcase that looks great in photos may lack durability, poor wheels, or weak zippers. Fashion-forward designs often sacrifice practicality.
What to do instead: Focus on build quality, wheel performance, and ergonomic design. A sleek bag is nice, but a reliable one is essential. Read reviews from real travelers, not just influencers.
❌ Mistake: Overlooking the Weight
Why it’s bad: A heavy suitcase reduces your packing capacity and increases the risk of exceeding weight limits. Some bags weigh 10+ pounds empty—leaving little room for clothes.
What to do instead: Choose a lightweight model made from polycarbonate or advanced composites. Aim for under 8 pounds. Test the weight in-store or check specs online.
❌ Mistake: Skimping on the Warranty
Why it’s bad: Luggage takes a beating. Without a solid warranty, you’re on your own if the zipper breaks or the wheel falls off after a year.
What to do instead: Invest in a brand with a strong warranty—ideally 5+ years or lifetime coverage. Brands like Briggs & Riley and Travelpro offer excellent protection.
❌ Mistake: Ignoring Expandability Limits
Why it’s bad: Expanding your bag at the airport may make it too large for the overhead bin. Some airlines measure expanded dimensions.
What to do instead: Choose an expandable model that adds only 1–2 inches and stays within carry-on limits. Test expansion at home before your trip.
❌ Mistake: Buying Based on Price Alone
Why it’s bad: The cheapest bag may save you $50 now but cost you $200 in replacements over time. Low-cost models often use inferior materials.
What to do instead: Think long-term. A $200 bag that lasts 10 years is a better value than a $80 bag that fails after two trips. Consider cost per use.
❌ Mistake: Not Testing Before Buying
Why it’s bad: You can’t judge wheel smoothness, handle comfort, or zipper quality from a photo. What looks good online may feel awful in person.
What to do instead: Visit a store to test the bag. Roll it, extend the handle, open and close zippers, and check the weight. If buying online, choose retailers with easy returns.
Budget Guidelines: How Much Should You Spend?
- Entry-Level ($80–$150): What to expect… Basic functionality with decent materials. Look for polyester soft-shells or ABS hard-shells. Wheels and handles may be less durable. Brands like AmazonBasics, Rockland, and American Tourister offer affordable options. Best for occasional travelers or students.
- Mid-Range ($150–$300): Sweet spot for most buyers… High-quality polycarbonate shells, reliable spinner wheels, and solid warranties. Brands like Samsonite, Travelpro, and Monos dominate this tier. You’ll get excellent value, durability, and features like TSA locks and compression systems.
- Premium ($300–$600): For enthusiasts and professionals… Top-tier materials, advanced engineering, and superior craftsmanship. Expect features like silent wheels, ergonomic handles, and lifetime warranties. Brands like Briggs & Riley, Tumi, and Rimowa excel here. Ideal for frequent flyers and business travelers.
- Luxury ($600+): Top-tier features… Aluminum shells, bespoke designs, and exclusive materials. These bags are as much about status as function. Rimowa, Globe-Trotter, and Tumi offer models in this range. Best for luxury travelers who value aesthetics and brand prestige.
Expert Tips for Getting the Best Deal
- Buy during off-season sales: Luggage is often discounted in January (post-holiday) and August (back-to-school). Airlines also promote travel deals during these times.
- Shop at authorized retailers: Avoid counterfeit bags by buying from brand websites, department stores, or authorized dealers. Check the brand’s official site for a list of approved sellers.
- Sign up for newsletters: Many brands offer 10–15% off your first purchase. You’ll also get alerts for flash sales and exclusive promotions.
- Check return policies: Choose retailers with at least 30-day return windows. This gives you time to test the bag and return it if it doesn’t meet expectations.
- Look for bundle deals: Some brands offer discounts when you buy a carry-on with a personal item or packing cubes. These can add value without extra cost.
- Consider refurbished models: Brands like Samsonite and Travelpro sell certified refurbished bags at 30–50% off. These are inspected, repaired, and come with warranties.
- Test in-store before buying online: Visit a store to evaluate comfort and build quality, then order online for better pricing or availability.
- Read the fine print on warranties: Some warranties exclude “normal wear and tear” or require you to pay for shipping. Understand what’s covered before you buy.
Frequently Asked Questions
Q: Can I bring an expandable carry-on on every flight?
A: Not necessarily. While most airlines allow carry-ons up to 22 x 14 x 9 inches, expanded dimensions may exceed this limit. Always measure your bag when expanded and check your airline’s policy. If in doubt, pack it unexpanded until you’re past security.
Q: Are hard-shell or soft-shell suitcases better?
A: It depends on your needs. Hard-shell bags offer better protection for fragile items and a sleek look, but they can scratch. Soft-shell bags are lighter, more flexible, and often have external pockets, but they offer less structure. For frequent flyers, hard-shell polycarbonate is usually the best choice.
Q: How much should a good carry-on weigh?
A: Aim for 6–8 pounds when empty. Anything over 9 pounds reduces your usable packing space. Lightweight models from brands like Monos and Away weigh around 6.5 pounds.
Q: Do I need a TSA lock?
A: Not required, but highly recommended. TSA locks allow agents to inspect your bag without damaging it. Most modern suitcases come with built-in TSA-approved locks.
Q: Can I check my carry-on if it’s too big?
A: Yes, but you’ll likely pay a checked bag fee. Some airlines allow oversized carry-ons to be checked at the gate for free, but this isn’t guaranteed. It’s better to choose a compliant size.
Q: How long should a carry-on last?
A: A quality bag should last 5–10 years with regular use. Look for brands with strong warranties and durable materials. Proper care—like cleaning wheels and avoiding overpacking—can extend its life.
Q: Are spinner wheels better than two-wheel models?
A: Spinner wheels (four wheels) offer better maneuverability in tight spaces and are ideal for flat surfaces. Two-wheel models are more stable on uneven terrain and often more durable. Choose based on your travel style.
Q: Can I use my carry-on as a personal item?
A: No. A carry-on is separate from your personal item (like a backpack or purse). Most airlines allow one of each, but the carry-on must fit in the overhead bin.
Q: What’s the best way to clean my luggage?
A: For hard-shell bags, use a damp cloth with mild soap. Avoid harsh chemicals. For soft-shell bags, spot-clean with a gentle detergent. Always air dry completely before storing.
Q: Should I buy a suitcase with a built-in USB port?
A: Not recommended. Built-in USB ports are often low-quality, drain battery life, and can’t be replaced if they fail. Use a portable power bank instead—it’s more reliable and versatile.
Our Final Recommendations
- Best for Budget-Conscious Buyers: Samsonite Winfield 3 Expandable – At around $150, it offers polycarbonate durability, smooth spinner wheels, and a TSA lock. A reliable choice for occasional travelers.
- Best Overall Value: Monos Carry-On – Priced at $220, it combines sleek design, lightweight polycarbonate, and excellent customer service. Includes a 10-year warranty and comes in multiple colors.
- Best Premium Option: Briggs & Riley Baseline Expandable Carry-On – At $450, it’s built to last a lifetime. Features a lifetime warranty, compression system, and silent wheels. Ideal for frequent flyers.
- Best for Beginners: Travelpro Platinum Elite – Around $200, it’s designed by flight attendants and offers excellent ergonomics, durability, and organization. Great for first-time buyers.
- Best for Advanced Users: Rimowa Essential Lite – At $650, it’s a luxury icon with aluminum corners, lightweight polycarbonate, and a minimalist design. Perfect for style-conscious travelers who demand performance.
Conclusion: Making the Right Choice
Choosing the right carry-on expandable rolling luggage isn’t just about picking a bag—it’s about investing in a travel companion that will serve you well for years to come. From airline compliance and durability to wheel performance and warranty coverage, every detail matters. By focusing on your specific needs—whether that’s budget, frequency of travel, or style—you can find a suitcase that’s not only functional but also a joy to use.
Remember, the best luggage is the one that disappears into the background, letting you focus on the journey, not the gear. Don’t be swayed by flashy features or aggressive marketing. Instead, prioritize quality, reliability, and long-term value. Test before you buy, read real reviews, and choose a brand you can trust.
Travel is unpredictable, but your luggage shouldn’t be. With the insights from this guide, you’re now equipped to make a confident, informed decision. So pack smart, travel light, and enjoy the freedom that comes with having the perfect carry-on by your side. Safe travels!
