SA062 Aluminium-Frame Hard Shell Luggage

SA062 Aluminium-Frame Hard Shell Luggage for OEM and ODM Programmes

Luggage factory since 2000, making vacuum-formed PC and ABS hard shells alongside PP injection, running OEM and ODM private-mould programmes, and exporting to Europe, the Americas, Korea and Japan.

SA062 specification

What a brand can change on this model

Because the shell is vacuum formed in house rather than bought in, customisation is not limited to a logo on a stock case. The shell design itself can be developed: the surface pattern and ribbing, the proportion, and the corner treatment. On top of that the shell material, the exterior colour against a Pantone reference, the lining and the lock are specified by the brand.

One constraint comes with the process. In vacuum forming, the wheels and the trolley are shaped to fit the mould, so their design is fixed on this model. Their colour can still be specified. Everything that does not have to match the mould — the shell material, the colour, the lining and the lock — stays open to the brand.

Tooling cost and minimum order

Shell tooling is charged by case size at RMB 200 per inch, equivalent to USD 31 per inch. A 20 inch shell therefore carries a tooling cost of RMB 4,000, or USD 620. The minimum order is 300 pcs per colour per size. Because no stock is held, every order is produced against your own colour and your own shell design rather than pulled from a warehouse.

The case behind a brand launch

SA062 is the model a Korean brand built its first range on. KIKO placed their opening order at our minimum of 300 pcs. Six years later that same line was shipping up to 12 containers in a single month. For a brand starting from zero, that is what a 300 pcs minimum is supposed to make possible: a first order small enough to commit to, on tooling that can carry the programme to volume.

Two programmes built the same way

The point of a private-mould programme is that the case no longer has to be a catalogue item. These are two projects delivered on the same vacuum-formed shell and aluminium frame platform. Client names are withheld under our confidentiality terms.

A 132 cm guitar case for a US music brand

• Brief. A young American brand needed a guitar flight case for touring musicians: strong enough to survive airline baggage handling, light enough to carry, and recognisable as their own product rather than a generic road case.

• Constraint. 132 cm tall and 40 cm deep, non-standard in both directions. The shell had to resist scratching and hold its shape under loaded transit without deforming or cracking. The surface needed the brand's own embossed texture, and the lock had to be TSA accepted.

• What we did. Formed the shell in pure polycarbonate and developed the anti-scratch texture into the tool itself. Built the closure on a thickened aluminium alloy frame. Added two metal brackets inside to stiffen the lid against point loads, and cut a custom foam interior in the exact profile of the instrument so nothing moves in transit. Fitted an inset TSA combination lock.

• Outcome. Passed the tumble test. First order 300 pcs, since reordered several times, eight years of continuous supply, and three further sizes developed from the same platform.

A 50 mm poker chip case for Germany's leading poker brand

• Brief. The top-selling poker brand in Germany wanted a presentation case for chip sets, sold as a premium product rather than transport packaging.

• Constraint. Only 50 mm of total internal depth to work with, which rules out standard frame hardware. The exterior had to read as high-end, and the surface needed the brand's own embossed texture.

• What we did. Formed the shell in pure polycarbonate with an anti-scratch texture. Developed an ultra-narrow aluminium alloy frame and matched small clasps to it, finished in black by anodising. Built the interior in EVA and EPP to hold the chips in place, and packed in a matte poly bag inside a premium rigid gift box.

• Outcome. Passed quality testing. First order 1,000 pcs, reordered several times, six years of continuous supply, and several further sizes developed.

Both projects started as a drawing and a quantity. If your product does not fit a standard case, that is the normal starting point rather than an exception.

Factory capability behind this model

• Manufacturing luggage since 2000, with 200 staff in a 30,000 square metre factory in Dongguan, Guangdong.

• Output of 8,800 pcs per day, supported by 5 injection machines, 2 sheet machines, 12 vacuum forming machines, 60 sewing machines and 8 assembly lines.

• Audited to ISO9001, Sedex and WCA, with models tested to REACH for the European and American markets.

• Components from HINOMOTO, YKK and YIF, including the trolley supplier used by Samsonite.

• Around 70 percent of output exported, to markets including Singapore, South Korea, Japan, Poland, the UK, France, the USA and Brazil.

Frequently Asked Questions

Is SA062 a zipper case?
No. The two shell halves are joined by a thickened curved aluminium alloy frame rather than a zipper.

Which shell materials are available?
New non-toxic ABS+PC is standard. ABS and pure polycarbonate are available on request.

What is the minimum order?
300 pcs per colour per size.

Is any of it held in stock?
No. Every SA062 is made to order, which is what allows the colour and the shell design to be specified by the brand.

Can we use our own shell design?
Yes. Tooling is charged at RMB 200 per inch, or USD 31 per inch. For a 20 inch shell that is RMB 4,000, or USD 620.

Can you make a size that is not in the catalogue?
Yes. Both projects above are non-standard sizes, and the guitar case is 132 cm tall.

How long does sampling take?
3 days for a standard style, and from 14 days for a customised style.

What sizes are available?
20, 24 and 28 inch, at 3.6, 4.3 and 5.2 kg net.

Ready to quote a private-mould programme?
Send the shell design or reference, the size mix and your estimated quantity, and we will come back with a tooling quotation and a unit price for the material you choose.