Carbon fibre composites enhances luggage design

Chinese luggage brand TUPLUS has released a new carbon fibre suitcase under its “Core” lineup. The 25-inch model, currently only available for sale in China, has front and back shells made of Maezio® thermoplastic composites from Covestro, boosting impact performance while elevating design and style.

Founded in 2015, TUPLUS is a special travel brand for high-end suitcases that have carried off many international prizes including the Red Dot Design Award. The new model features a creative multi-material design concept: The structural frame in the centre is made of aluminium and magnesium alloy, while the front and back shells have been given the highly-coveted look of carbon fibres. It is also designed with an advanced lock system featuring the absence of rivets and screws, giving it a smooth, minimalist finish.

Despite the dramatic decrease in travel due to the corona crisis, TUPLUS believes the travel industry will bounce back steadily as travel restrictions are eased in China and the world. “People haven’t changed in that they still want to travel, but we need to adapt to the new times ahead and to the new needs of tourists to feel safer,” says Catherine Jiang, President and CEO of TUPLUS. “High-quality materials are always at the heart of our design concept because we know our customers rely on them for travel safety and security. Covestro’s Maezio® composites have allowed us to take advantage of the superior strength and premium value of carbon fibre, to offer our customers enhanced protection and an entirely new travel experience.”

Performance meets design
On and off airplanes, in and out of car trunks, natural wear and tear – luggage needs to be robust. Maezio® thermoplastic composites are based on a polycarbonate matrix system. The intrinsic toughness of polycarbonate has made it a staple material for hard-shell suitcases for decades. Carbon fibre reinforced polycarbonate composites take stiffness and impact resistance to a new level. They can reduce the risk of damage and deformation, even when compared to metal, without adding weight.

Rigorous safety tests ranging from drop and tumble tests to falling ball impact tests have shown better impact resistance of composite shells compared to aluminium. This means the material can better protect articles in the luggage against perils, in particular sensitive equipment like cameras and high-end electronics.

A suitcase built to last also needs to look good. With a natural, unidirectional carbon fibre appearance, Maezio® composites break away from the traditional woven look of carbon fibre, while striking a chord with natural materials like wood in its looks and aesthetics. The simplicity and authenticity of that visual language is a good source of inspiration for designers.

Designed for scale
Performance and design are only the starting points for luggage manufacturers however, as they need to integrate new materials which can also be manufactured cost-efficiently at scale. Despite its popularity, carbon fibre luggage is known to be labouriously hand-crafted, driving up costs and making them difficult to scale.

Maezio® materials, on the other hand, are thermoplastic composites, which can be thermoformed efficiently at high yield rates and low cycle times, making them ideal for mass production. Not all carbon fibre suitcases need to be thermoformed however – the unique design of the front and back shell structures of TUPLUS luggage allows composite sheets to be integrated directly into the production line and assembled after proper cutting and coating. This design approach is unique to expedite the scaling of carbon fibre suitcases.

“We believe our thermoplastic composite solutions will accelerate the adoption of carbon fiber composites in luggage thanks to their unique performance, aesthetic and production advantages,” says Lisa Ketelsen, head of the thermoplastic composites business of Covestro. “Meanwhile, we’re also working on thermoformed, 3D luggage cover solutions to make composites available for a wide range of suitcases and allow more and more consumers to enjoy the performance and lifestyle benefits of composites.”