Matty Benedetto 3D Prints a Carry On Suitcase Loaded With Every Airport Convenience

Product designer Matty Benedetto discovered some clips of passengers stranded in airport security lines and clogged airport terminals. He determined that his next trip needed to be less of a nightmare, so he set out to design a carry-on suitcase that would make the entire experience a little less stressful. More specifically, he decided to create one from scratch using his 3D printers.

He tailored the dimensions of his carry-on to normal sizes so that it would pass through security inspections without a second thought. Then he divided the bag’s main body into two parts with overlapping edges to provide strength, and printed a few test copies with some colorful leftover filament to check how the pieces fit together. Putting it all together was like snapping a load of large plastic bricks into place, except he added metal hinges for the lid and a telescoping handle constructed from off-the-shelf components. During a print halt, ball bearings were inserted into the wheels to ensure that they roll smoothly without the need for any additional equipment.

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After determining the basic shape, he went on to the details that would make a long wait more bearable. A flat panel folds out from the front and includes a little latch to secure it in place, allowing you to prop up your laptop during a layover. A MagSafe mount appears next to it to hold your phone, allowing you to watch shows or check your messages without taking your hands off the wheel. When you’re stuck waiting for a delayed flight, it’s usually a good idea to have some food with you, so he included a little jar that twists open easily from the side, allowing you to access your goodies without having to unzip the main zipper.

On a long journey, coffee can pose a serious security issue, spilling all over the place and causing a huge mess. To avoid this kind of disaster, he created a cup holder with a sophisticated gimbal inside that maintains your drink level even when the bag tilts. On the outside, he incorporated a rotating dial that displays the flight number, weather prediction, destination details, and a few emergency contacts at a glance. And for further peace of mind, he designed the feet to detach so you can put an AirTag inside each one, which is entirely out of sight but provides some extra protection against losing your luggage.

The first major test was security, when his luggage breezed through the X-ray machine with no one blinking an eyelash about its printed design. Next, he had to get it into a regional flight, which proved difficult until he gave it a gentle nudge into the overhead bin, where it slipped in without incident. The smooth rolling was due to the ball bearings, and the entire setup weighed about the same as a conventional carry-on.

However, when he arrived at his destination, things became a little more problematic. There were hairline cracks all along the main seam, one of the wheels had broken free during the journey, the snacks in the jar had turned to crumbs, and a couple of the smaller attachments had vanished; not a bad outcome, all things considered.