By: Mae Cornes

When purchasing luggage, factors like durability and convenience are often considerations, but the materials used in your suitcase can also play a role in your overall well-being. Duravo, an emerging brand in the luggage market, is offering an alternative to the industry’s common reliance on polycarbonate, a material frequently used in hard-shell luggage.

Polycarbonate contains bisphenol A (BPA), a chemical compound linked to various health risks. By developing luggage made from its innovative, BPA-free Flexshell™ material, Duravo offers travelers a safer alternative without sacrificing strength or functionality.

The Risks of BPA in Polycarbonate Luggage

Polycarbonate is commonly chosen for hard-shell suitcases due to its lightweight and durable nature. However, one concern is that it contains BPA, a chemical used to strengthen plastics. The National Institute of Environmental Health Sciences notes that BPA can potentially enter the body through skin contact, inhalation, or ingestion. Some studies have suggested that prolonged exposure to BPA may be associated with hormone disruption, cardiovascular issues, and developmental concerns in children.

Polycarbonate luggage raises particular concerns because of its prolonged contact with personal items, such as clothing and toiletries, which can expose travelers to low levels of BPA over time. With more research highlighting the potential health risks, consumers are increasingly looking for alternatives that prioritize safety without compromising durability.

BPA Exposure: What the Research Shows

BPA is a chemical that can mimic estrogen, potentially influencing the body’s hormonal balance. Some studies suggest that prolonged exposure to BPA may impact brain development and behavior in children and could be linked to an increased risk of conditions like high blood pressure and Type 2 diabetes in adults. Since BPA is not quickly eliminated from the body, repeated exposure—such as frequent use of polycarbonate luggage—may contribute to its accumulation over time.

While some countries have banned using BPA in certain products, such as baby bottles and food containers, luggage has largely escaped regulatory attention. Yet, as the demand for healthier, chemical-free alternatives grows, luggage manufacturers must rethink their materials.

Dan Cooper, co-founder of Duravo, explains, “As people become more informed, they realize the importance of choosing products that prioritize their health. That’s where we saw an opportunity with Flexshell.”

Duravo’s Flexshell: A Safer, Stronger Alternative

Duravo’s solution to the problem of BPA in luggage is its Flexshell™ technology, a patented composite that combines high-strength fibers of polypropylene, a BPA-free polymer. Unlike polycarbonate, polypropylene does not release harmful chemicals and has a significantly lower environmental impact. Flexshell is designed to withstand the rigors of travel, offering impact resistance, flexibility, and lightweight performance—essential for today’s frequent flyers.

“With Flexshell, we wanted to create a material that offers the same, if not better, durability than polycarbonate but without the associated health risks,” says Matt Muhr, Duravo’s co-founder. “Our goal was to make something that travelers could feel confident using, knowing it’s safe for them and their families.”

By avoiding BPA and other harmful chemicals, such as volatile organic compounds (VOCs) and PFAS, Flexshell offers a solution for health-conscious travelers who want more than just a functional suitcase. 

Environmental Impact, Sustainability, and Performance Without Compromise

Duravo’s commitment to safety extends beyond human health, addressing the environmental drawbacks of polycarbonate, particularly its difficulty in recycling, which contributes to a growing plastic waste problem. Like many other hard-shell plastics, polycarbonate suitcases are not easily broken down or repurposed, adding to the waste burden once discarded. In contrast, Duravo emphasizes sustainability in its design. The thermoplastic process used to manufacture Flexshell eliminates harmful solvents and volatile organic compounds (VOCs), making it a cleaner option for the environment. Flexshell’s enhanced durability also ensures longer-lasting suitcases, reducing the need for frequent replacements—an essential consideration for travelers conscious of their environmental footprint.

Beyond health and sustainability, Duravo’s Flexshell luggage also delivers exceptional performance. The material’s high tensile strength allows for thinner yet stronger luggage walls, creating more packing space without adding extra weight. At only five pounds, Duravo’s International Expandable Carry-On is one of the lightest in its category while still offering up to 46 liters of packing volume. Additionally, the company integrates modern features such as USB charging ports, AirTag pockets, and compression straps, ensuring that travelers not only have a safer, more environmentally friendly suitcase but also one that enhances convenience and ease of travel.

Shifting Consumer Preferences

As health and environmental concerns take center stage, consumer preferences are shifting away from traditional materials like polycarbonate. Increasingly, travelers are seeking products that align with their values, whether that means choosing BPA-free luggage for health reasons or opting for eco-friendly materials to reduce their carbon footprint.

Cooper reflects on this change: “We’re seeing more people question what their products are made of. They want to know that their luggage is safe and made responsibly. Flexshell addresses both those concerns.”

Research continues to highlight the potential risks of BPA and other harmful chemicals, so the demand for alternative materials in consumer goods is likely to grow. Duravo’s Flexshell technology exemplifies how the luggage industry can evolve to meet these changing expectations.

Published by: Nelly Chavez