Luggage文章 - designBackpack

Luggage Manufacturing Process for Custom Orders

When you are ordering a custom suitcase, the clearer your design and material specifications, the smoother the process. Below is a detailed workflow.

You should provide a clear design drawing and a design concept, including both external and internal dimensions, compartments, materials, and desired finishes.
Provide the correct Pantone colour code so we can match the colour accurately during production.
Based on your design documents and requirements, we begin arranging the project.

Step 1: Our design team creates a 3D model of the suitcase based on your drawings.
Once the 3D model is complete, we render images and send them to you for approval.
After your confirmation, we begin mould opening (tooling). The mould lead-time depends on the complexity of the case.
Important tip: Please make sure your design documents are final before mould opening. Once the mould is made, any changes mean the old mould is unusable and a new one must be made, which causes cost waste.

After mould completion, we proceed to shell formation: We select materials according to your requirements and the design.
Common materials used for hard-shell luggage include PP, ABS, and sometimes PU (for overlays or soft-touch finishing).
- PP is lightweight, flexible, and offers good durability.
- ABS is cost-effective, allows good colouring, but may be less resistant to extreme impact compared to higher-end materials.
- PU is often used for soft-side bags or as a finishing layer rather than as full shell material; if used in hard-case context it’s usually for texture/overlay rather than structural shell.
We begin the shell forming process (injection moulding or vacuum forming) using the mould, apply colour (matching your Pantone code), and assemble the shell halves.

We plan capacity according to your order quantity: machine allocation, manpower scheduling, batch planning.
The production workflow is divided into phases such as: shell forming → shell finishing/colouring → interior lining & accessories → assembly of handles/wheels → final inspection.

Depending on material, we use either injection moulding (often for PP) or vacuum/pressure forming (often for ABS, PC).
Shell halves are formed, trimmed and prepared for assembly.
While the shell is being formed, accessories such as wheels, telescopic handle sets, corner protectors are prepared for installation.

Components such as lining fabric, internal compartments, straps, compression panels are produced.
Handles and hardware (zippers, locks, telescopic system) are installed.
If you specified PU overlays, embossing or texture, that is done at this stage.

The formed shell halves, internal components, hardware are brought together.
Assembly includes: fixing wheels, attaching handle systems, fitting zippers, installing branding/logo, and sealing shell edges.
Final finishing includes cleaning up seam lines, removing flash, smoothing edges, checking that colours and finishes match expectations.

We perform structural tests: drop-tests, shell impact tests, wheel and handle endurance tests.
Visual inspection: shell surface finish, colour correctness (Pantone match), branding, lining cleanliness.
Dimensional checks: ensure overall dimensions match your drawing and any airline/regulatory requirements.
Packaging inspection: ensure no residues, dust, or manufacturing residues remain.

Each piece is cleaned, dust-free, thread-free.
Packing according to your custom packaging instructions: polybag, dust cover, box packaging, customised hang tags, brand cards.

Finished goods are stored in batch-specific locations, inventory recorded.
Logistics arranged as per your preference: sea freight, air freight, or courier. Pre-shipment check ensures correct quantity, model, and packaging mark.

We stay in touch with you for feedback on usage and performance.
Any quality issues reported will lead to repair/replacement or process improvement.
Issue logs are kept for continuous manufacturing improvement.

Here are key points for the typical materials used in hard-shell luggage manufacturing and what to pay attention to:

Lightweight and flexible, good for frequent travellers where luggage weight matters.
Good resistance to low temperatures and certain chemicals.
However, may have more visible surface scratches compared to harder materials.
When used in injection moulding, mould cost is high but scrap is low.

Economical option, good mouldability and colour options.
Lower impact resistance compared to PP or PC; more vulnerable under extreme loads.
Good option when cost control is important and usage is moderate.

Often used for overlays, soft-touch finishes, or soft-side luggage shells rather than primary hard shell.
Offers premium texture, comfort feel, but may increase cost and reduce structural rigidity if used incorrectly.

Colour matching: If you require a specific Pantone colour, ensure the resin or shell coating process supports precise pigment matching.
Moulding method: Injection moulding vs vacuum forming influences shell strength, weight, cost, and waste.
Sustainability: For example, RPET or recycled shell materials are emerging in the market.

Provide your design drawing (internal + external), specify materials, colours (Pantone), and functions.
Once approved, 3D modelling → rendering → mould opening (be final on design to avoid costs).
Shell forming with your chosen material (PP, ABS, PU overlay etc).
Assembly of internal/external components, finishing and inspection.
Cleaning, packaging, shipment, and after-sales follow-up.