Michael Turner
Measure before purchase: compare the external height, width and depth of the smaller unit with the usable interior height of the larger one (subtract wheel thickness and collapsed-handle clearance). Typical model ranges: 20″ models ≈ 21–23 in total height, 24″ ≈ 25–27 in, 28″ ≈ 29–31 in. If the larger unit’s internal shell depth is at least 1.5 in greater than the smaller unit’s total depth, nesting is probable without deforming shells or straining zippers.
Practical steps to nest safely: fully empty the smaller case, retract telescoping handle, fold or remove any removable pockets/organizers, close expansion zippers on both shells, angle the smaller case into the larger and align wheel housings so they don’t press against the interior wall. Leave a minimum clearance of 0.5–1 in around edges to avoid long-term stress.
Buying checklist (quick): 1) compare manufacturer external dimensions and internal usable depth; 2) prefer clamshell designs with flush wheels and low-profile handles; 3) avoid models with large external pockets or protruding trims on the smaller unit; 4) if possible, test nesting in-store or buy a set sold as nested – that guarantees compatibility.
Nesting compatibility for this brand’s suitcases
Recommendation: purchase matching-set pieces (carry-on ~20–22″, mid 24–26″, large 28–30″) because smaller units will typically nest within larger shells when height difference is ≥2″ and depth difference is ≥0.5–1″.
- Which cases nest: hard-shell polycarbonate spinner sets with recessed wheels and flush telescoping handles nest reliably; soft-sided designs with external pockets or rigid frames usually will not.
- Required clearances: allow ~1–2″ clearance around wheel housings and 0.25–0.75″ for zipper lips; if product specs list overall heights (including wheels/handles), subtract wheel thickness (typically 0.75–1″) to compare usable nesting height.
- How to check before purchase: compare exterior height/width/depth specs and confirm wheel-to-wheel spacing; look for manufacturer notes such as “nesting” or “stackable” on product pages or packaging.
- Prepare pieces: empty shells, remove packing cubes, fully collapse the telescoping handle.
- Align orientation: place the larger case upright on a flat surface, set the smaller face-down with wheels toward the larger case’s wheels so wheel housings nest without collision.
- Protect finishes: insert a thin microfiber towel or the dust bag between shells to prevent scratches where edges meet.
- Secure for storage: zip the outer case about halfway, fasten internal compression straps, and use a luggage strap around the closed set if you need to stack multiple nested sets.
When nesting fails: check for mismatched collections, oversized external pockets, fixed telescoping-handle housings, or wheel pods that protrude beyond the outer shell profile; replacing or removing wheel housings is not recommended unless performed by a certified repair center.
Storage tip: for small accessories, rigid handles and umbrella frames, see best way to store an umbrella rig for compact organization methods that work well inside nested suitcases.
Which sizes and collections are compatible for nesting?
Short recommendation: For the brand’s hard-shell spinner lines, standard size progressions nest reliably when expansion zippers are closed and telescoping handles are fully retracted – 20–22″ carry-on units nest into 24–26″ medium shells, and those medium shells nest into 28–30″ large shells.
Specific commonly compatible pairings: 20″ → 24″, 20″ → 28″, 22″ → 26″, 24″ → 28″. Measured external dimensions typical by category: carry-on 20–22″ (approx. 55–56 cm tall, 35–38 cm wide, 22–24 cm deep), medium 24–26″ (≈ 61–66 cm tall, 40–44 cm wide, 26–30 cm deep), large 28–30″ (≈ 71–76 cm tall, 47–51 cm wide, 30–33 cm deep).
Verification rule: a smaller shell’s maximum external width and depth should be at least 1.5–2.5 cm (0.6–1.0 in) less than the larger shell’s usable internal width/depth, and height should allow 3–5 cm (1.2–2.0 in) clearance to accommodate wheel housings and internal lining. If a manufacturer lists internal usable dimensions, use those; otherwise measure internal cavity at the widest points with the liner flattened.
Collections that share identical shell moulds, wheel housings and recessed telescoping mechanisms (hard-shell spinner, non-textured matte spinner, and the brand’s expandable spinner family when zipped closed) are cross-compatible for nesting. Models with radically different shell geometry (boxy vs strongly curved fronts), external wheel housings, or fixed external pockets often block nesting despite similar nominal sizes.
Practical checklist before attempting nesting: empty both cases; retract handles; close expansion zippers; remove hang-tags, packing cubes and hard dividers; test placing the smaller into the larger at a slight angle to clear wheels. If the smaller resists with more than light pressure, do not force – that combination is not compatible.
Quick exceptions: expandable models zipped open usually add 2–4 cm (0.8–1.6 in) depth and will not nest into the next size unless compressed; collections with thick molded interiors or built-in toiletry panels commonly prevent nesting regardless of nominal inch size.
Measure exterior and interior dimensions to confirm nesting
Compare the smaller case’s external width, height and depth to the larger case’s usable internal clearances and allow minimum margins: hard shells – 10–15 mm lateral clearance per side; soft-sided models – 20–30 mm per side; vertical clearance 20–30 mm if wheels or raised handles are present; wheel housings and recessed pockets: add 5–10 mm tolerance.
Exterior measurement procedure: measure with telescoping handle fully retracted and any external straps or bumpers in their storage position. Record three values: Hext (ground to top), Wext (widest point across faces including wheel housings and corner guards) and Dext (face-to-back including wheel projection). Use a rigid tape measure for general checks and calipers for critical tolerances under ±5 mm.
Interior measurement procedure: open the case and measure usable floor width (Wint_floor), usable floor depth (Dint_floor) and usable vertical clearance to the lid when closed (Hint_clear). Measure at the narrowest internal location (near wheel wells, corners, or frame rails). Measure rim/opening dimensions (Wint_rim and Dint_rim) because an interior that is wider below the rim is unusable if the rim is smaller. Subtract liner and frame thickness from any manufacturer shell figures to get true usable values.
Quick verification formula and example: require Wext ≤ Wint_rim − 2×margin and Dext ≤ Dint_rim − 2×margin and Hext ≤ Hint_clear − vertical_margin. Example: smaller case Wext 40.0 cm, Dext 20.0 cm, Hext 55.0 cm; larger case usable interior Wint_rim 44.0 cm, Dint_rim 25.0 cm, Hint_clear 58.0 cm; available lateral clearance = (44.0−40.0)=4.0 cm → 2.0 cm per side (meets 1.0–1.5 cm per-side requirement for hard shell), depth clearance = 5.0 cm → acceptable, vertical clearance = 3.0 cm → acceptable once wheel/handle projections verified.
Practical checks: confirm zipper/rim opening width before attempting to insert; measure wheel hub thickness and handle pocket depth separately; test a mock assembly using cardboard or foam cut to the smaller case’s external outline if a physical trial is not possible; mark the narrowest measured dimension and compare against the rim opening as final pass/fail.
Nesting hard-shell cases: hinge clearance and rim overlap rules
Recommendation: require minimum hinge-axis clearance of 18–22 mm and rim-overlap allowance of 6–10 mm; verify with the formula and checklist below before attempting to nest two shells.
Measurements and formulas
Measure these values with a caliper at the mouth of the outer shell and at the seam line of the inner shell:
– Outer internal gap (G_o): distance from inner face of outer shell rim to the opposite inner face, measured perpendicular to the opening.
– Hinge protrusion (P_o): maximum projection of hinge hardware into the outer mouth plane.
– Inner rim thickness (R_i): radial lip thickness that will overlap the outer rim when nested.
– Inner shell wall thickness (S_i): outer wall of the inner shell measured at the rim region.
Required clearance formula: Required_G = P_o + R_i + S_i + T_allowance, where T_allowance = 3–5 mm for easy insertion. Condition for safe nesting: G_o ≥ Required_G.
Example calculation: P_o = 10 mm, R_i = 6 mm, S_i = 3 mm, T_allowance = 3 mm → Required_G = 22 mm; proceed only if G_o ≥ 22 mm.
Practical tolerances and special cases
– Zipper/Seal compression: if an outer shell has a compressible zipper gasket, add 2–4 mm to Required_G to prevent seal deformation during insertion.
– Offset hinges (hinge mounted to the exterior edge): increase P_o estimate by the hinge shell-thickness plus any screw-head projection; treat as P_o + 2–6 mm depending on hardware.
– Multiple nesting (more than two shells): add 1 mm extra clearance per additional nested layer beyond two to avoid progressive interference.
– If one shell has a recessed rim that overlaps into the cavity (O_o), subtract O_o from G_o before comparing to Required_G (use G_o_adj = G_o − O_o).
| Parameter | Symbol | Recommended value / example | How to measure |
|---|---|---|---|
| Outer internal gap | G_o | ≥ Required_G (example target ≥ 22 mm) | Caliper across opening from inner rim face to inner face opposite |
| Hinge protrusion | P_o | Typical 6–14 mm; use exact measured value | Measure from shell rim plane to highest hinge point |
| Inner rim thickness | R_i | Common 4–8 mm | Measure radial lip that will overlap outer rim |
| Inner wall thickness | S_i | Typical 2–5 mm | Measure shell wall at rim with caliper |
| Allowance for handling | T_allowance | 3–5 mm standard; +2–4 mm if zipper seal present | Apply to Required_G |
| Practical example | – | Small→Medium: P_o=10, R_i=6, S_i=3, T=3 → Required_G=22 mm | Confirm G_o ≥ 22 mm before nesting |
Quick tip: perform a dry run with soft spacers (cardboard strips of known thickness) placed along inner rim to simulate Required_G; if insertion proceeds without catching, proceed with actual shells. For unrelated gear recommendations, see best digital camera for 90s look.
Preparing wheels, handles and zippers before nesting to prevent damage
Remove detachable wheels; fully retract and lock the telescopic handle; secure all zipper pulls with a 3–4 mm nylon zip-tie; pad wheel housings with 10–20 mm closed‑cell foam strips before placing one case into another.
Wheels: if removable, use a Phillips #1 driver to detach, label orientation, and store fasteners in a small resealable bag taped to the lid. If non‑removable, rotate spinner housings toward the shell and immobilize the axle with a 25–50 mm gaffer tape band. Measure wheel housing protrusion – anything >30 mm should be removed or padded to avoid concentrated pressure points.
Padding for wheels: cut closed‑cell foam 10–20 mm thick into strips 25–50 mm wide and position between each wheel housing and the opposing shell surface. Secure foam with 25 mm cloth tape in two perpendicular strips. For heavier models, double the foam thickness to 30–40 mm at points where wheels meet the shell.
Telescopic handle: retract fully and verify the lock engages. Slide a 10–15 mm foam pipe sleeve over exposed tubes or wrap with a folded microfiber towel and secure ends with 25 mm cloth tape. If the handle is removable, remove it following manufacturer instructions, keep washers and screws in the labeled bag, and affix the bag to the interior wall with clear tape.
Zippers: align pulls at the midpoint and close them. Run a 3–4 mm nylon zip‑tie through both pulls, trim flush to 3–5 mm, then cover the trimmed end with a 10 mm piece of fabric tape to prevent abrasion. For long storage or tight nests, add a 3–5 mm foam strip along the zipper seam to prevent shear stress when pressure is applied.
Final arrangement: place a 12–25 mm folded towel or foam pad over the handled/wheeled area of the inner case and secure it with two crosswise 50 mm straps or tape so nothing shifts during placement. Insert silica gel packet(s) near metal fasteners to limit corrosion. Avoid over‑compressing padding – total added thickness at contact points should not exceed 40 mm to prevent zipper distortion or handle bending.
Workarounds when their suitcases won’t nest: padding, adapters and alternate storage
Primary recommendation: choose one of three approaches – protective shimming to allow partial stacking, custom spacers/adapters to restore alignment, or change to alternate storage that saves floor volume.
Protective shimming: use closed-cell EVA foam strips (2–6 mm thick) or felt adhesive tape (1–3 mm) applied to the inner rim and corner lips to prevent abrasion and create a controlled gap. Target 5–12 mm total clearance around the perimeter so shells contact only foam, not hard edges. Adhesive-backed rubber corner pads (20 × 20 × 5 mm) work well at three contact points to stabilize rotation without stress on hinges.
Off-the-shelf spacer adapters: use 1″ (25 mm) PVC coupling rings cut into 8–12 mm tall collars and bonded with removable double-sided tape at four equidistant points around the lower shell; this raises the lower shell uniformly and compensates for rim overlap. For a cleaner solution, mount self-adhesive silicone feet (Ø15–20 mm, height 8–10 mm) at 45° intervals so the inner case seats on soft feet rather than metal or plastic edges.
Custom printed adapters: design a ring with an inner recess matching the outer perimeter of the smaller shell plus +6 mm clearance, wall thickness 3–4 mm, lip height 8–12 mm. Include 3–4 tab holes (Ø4 mm) for removable zip-ties or threaded inserts. Print in PETG or TPU for slight give; PETG for rigid support. Mount with painter’s tape as a non-permanent interface to protect finishes.
Non-invasive securing: use 20–30 cm length Velcro straps (25 mm wide) wrapped and overlapped under the nested stack to prevent sliding; choose loop/ hook rated for 15–25 kg. For temporary hold in transit or storage, ratchet straps with soft protectors across the pair produce uniform compression but keep torque minimal on hinges – set tension so compression force stays under 30 N per strap to avoid shell deformation.
Alternate storage techniques: for soft items, vacuum compression bags reduce volume by 35–65% – select heavy-duty bags (≥90 µm thickness) and sizes aligned to the case interior (e.g., 80 × 100 cm for medium duffels). For hard-shell models, vertical storage on wheels (handle extended) on a narrow shelf 10–30 mm from adjacent items reduces footprint; recommended shelf depth 40–50 cm for medium shells, 55–75 cm for large. Wall hooks rated 25–40 kg mounted into studs at 45–60 cm centers allow hanging by the retracted handle saddle if handle loop exists.
Space-saving furniture: use a freestanding rack with three-tier slots spaced 8–12 cm vertically for short-term stacking, or a slim metal cabinet with internal width 55–70 cm and depth 35–45 cm to store two medium shells side-by-side. Under-bed placement requires total shell height <14 cm; measure profile with wheels depressed to confirm clearance before sliding.
Damage and warranty precautions: avoid permanent drilling or adhesive that may void warranty. Test adhesives on an inconspicuous area for 48 hours; remove with isopropyl alcohol and a plastic scraper. Keep hinge torque minimal when using spacers; if any hinge binding occurs, remove spacer immediately and re-evaluate spacer height by +2 mm increments until rotation is free.
Quick checklist before final storage: 1) Confirm 5–12 mm perimeter clearance with protective pads in place. 2) Verify hinge rotation and zipper alignment without resistance. 3) Secure stacked pair with soft Velcro or strap below 30 N compression per strap. 4) Label orientation with masking tape arrow and date. 5) Recheck after 24 hours for adhesive migration or deformation.
