A lot goes into a case that is meant to last a lifetime of departures. This is what goes in.
Wheel bearings. Handle stops. The rivet under the corner guard. A great suitcase is decided in the places you will never look, so that is where we spent the time.
How it is made
Shell, lining, hardware and assembly happen under one roof. Nothing is outsourced across three suppliers and stapled together at the end. These are the steps, filmed on our line.
01 Materials
It starts as polycarbonate and coloured sheet stock, kept on the floor until the line calls for it. We use 100% virgin polycarbonate, not regrind. Regrind is cheaper, and it is also how a shell cracks in a cold cargo hold.
02 Shell
Each half-shell is pressed in its mould, released and lifted out, then racked and left to settle before anything is cut.
03 Shell
A CNC machine follows the same path around every shell edge and cuts the openings, so the frame, zipper track and lid meet flush on every case.
04 Factory
Shell storage and the sewing floor sit under one roof. Every TROCHI case is built on the same line by the same team, which is the only way the tenth case matches the first.
05 Lining
Lining panels, compression straps and binding are machine-sewn and cut for one shell size.
06 Hardware
Corner guards, feet, handle mounts and wheel housings are riveted through the shell. Glue is faster on the line, and it is also the first thing to let go after a conveyor belt.
07 Assembly
Handles and hardware are prepared at the bench and assembled onto the case. The telescopic handle is an alloy assembly that locks at three heights.
08 Lining
The sewn lining goes into the shell and is smoothed and positioned by hand.
09 Assembly
The case edge is stitched and joined all the way round.
10 Inspection
The lining is pressed, details are finished, and every case is opened, closed and checked by hand.
11 Factory
Finished cases travel the overhead conveyor to final inspection and packing.
12 Packing
Each case is bagged, boxed and sealed at the end of the line.
Next
Wheel running, handle shock, telescopic handle cycling and drop tests, filmed on the rigs our cases go through.
TERRY 3.0 Carry-On
Carry-On
Trochi Charles Trunk Check-In Medium
Check-In Medium
