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How To Make A Suitcase


Modified: December 28, 2023

by Haleigh Winger



Traveling is an exciting and rewarding experience, but it can also be a challenge to pack everything you need into a limited amount of luggage. One crucial item when traveling is a suitcase, which serves as your trusted companion to carry all your essentials and accessories. While there are plenty of suitcases available on the market, creating your own can be a fun and personalized project that ensures your suitcase perfectly suits your needs and style.


In this article, we will guide you through the process of making your own suitcase from scratch. Whether you’re a sewing enthusiast looking for a new DIY project or someone looking to customize their travel gear, this step-by-step guide will help you create a functional and stylish suitcase that reflects your personality.


By making your own suitcase, you have complete control over its design, size, and features. You can choose fabrics that match your style, incorporate pockets and compartments for optimal organization, and add personal touches like embroidered initials or decorative patches. Plus, by customizing your own suitcase, you can ensure its durability and sturdiness, guaranteeing it will withstand the demands of frequent travel.


Before we dive into the step-by-step process, there are a few essential materials you will need to gather. Let’s take a look at what you’ll need to get started.


Step 1: Gathering Materials

Before you begin making your own suitcase, it’s important to gather all the necessary materials. Here’s a list of the items you’ll need:

  1. Fabric: Choose a sturdy and durable fabric that can withstand the rigors of travel. Nylon, canvas, or synthetic blends are good options. Make sure to select a fabric that matches your desired style and color scheme.
  2. Interfacing and Stabilizers: These materials will provide structure and support to your suitcase. Interfacing helps stiffen the fabric, while stabilizers reinforce key areas for added durability.
  3. Lining Fabric: Opt for a smooth and lightweight fabric to line the interior of your suitcase. This will give it a polished look and protect your belongings.
  4. Zippers: Choose high-quality zippers in various lengths, depending on the size of your suitcase and the compartments you plan to include.
  5. Handles: Look for sturdy and comfortable handles that can withstand the weight of your suitcase. Consider options like faux leather or nylon webbing.
  6. Thread: Ensure you have a strong thread that matches or complements the color of your fabric.
  7. Hardware: This includes items like D-rings, buckles, and snaps. Depending on your design, you may need these for straps, closures, or other functional elements.
  8. Sewing Machine and Tools: You’ll need a sewing machine capable of handling heavy-duty fabrics, as well as basic sewing tools like scissors, pins, measuring tape, and a seam ripper.
  9. Optional: Embellishments: If you want to add a personal touch to your suitcase, consider decorative elements like embroidery, appliques, or patches.

By having all these materials on hand, you’ll be well-prepared to start creating your own custom suitcase. In the next step, we’ll guide you through the process of measuring and cutting the fabric.


Step 2: Measuring and Cutting the Fabric

Now that you have gathered all the necessary materials, it’s time to measure and cut the fabric for your suitcase. Follow these steps:

  1. Measurements: Determine the desired dimensions of your suitcase. Consider the size restrictions of airline carry-on luggage or your personal preferences for checked luggage. Measure the length, width, and height of the main body of the suitcase, as well as any additional compartments or pockets you plan to incorporate.
  2. Add Seam Allowance: Add a seam allowance of about ½ inch (1.27 cm) to each side of the measurements. This allows room for sewing and ensures a proper fit. For example, if your desired suitcase dimensions are 20 inches (50.8 cm) by 14 inches (35.56 cm) by 8 inches (20.32 cm), you would cut the fabric to 21 inches (53.34 cm) by 15 inches (38.1 cm) by 9 inches (22.86 cm).
  3. Cut the Main Body: Use a sharp pair of fabric scissors to cut out the main body pieces of the suitcase according to the measurements you calculated. You will need a front piece, a back piece, two side pieces, and a bottom piece. Make sure to cut the fabric accurately and smoothly.
  4. Cut Additional Compartments: If you plan to include pockets or compartments in your suitcase, measure and cut the necessary fabric pieces accordingly. These can be sewn onto the interior or exterior of the suitcase, depending on your design.
  5. Cut Lining Fabric: Repeat the same steps to measure and cut the lining fabric, ensuring it matches the dimensions of the main body pieces. The lining fabric will be sewn to the inside of the suitcase, providing a finished and polished look.

Remember to double-check your measurements before cutting the fabric to ensure accuracy. Once you have all the fabric pieces cut, you’re ready to move on to the next step: sewing the main body of the suitcase.


Step 3: Sewing the Main Body of the Suitcase

With the fabric pieces cut, it’s time to sew the main body of the suitcase together. Follow these steps:

  1. Preparation: Set up your sewing machine with a heavy-duty needle and thread that matches the color of your fabric. Double-check that your machine is set to the appropriate stitch length and tension for the fabric you’re using.
  2. Assembling the Front and Back: Place the front and back pieces of the main body fabric together, right sides facing each other. Pin the edges in place to secure them. Starting at one corner, sew along the edges, leaving a ½ inch (1.27 cm) seam allowance. Continue sewing until you reach the next corner, leaving the top edge open for now. Repeat this step for the remaining three corners.
  3. Sewing the Sides: Attach the side pieces to the front and back of the main body. Align the edges and pin them in place. Sew along the edges, leaving a ½ inch (1.27 cm) seam allowance. This will create the box shape of the suitcase. Reinforce the corners with additional stitching to ensure durability.
  4. Attaching the Bottom: Take the bottom piece of fabric and align it with the edges of the assembled main body. Pin it in place and sew along the edges, leaving a ½ inch (1.27 cm) seam allowance. Reinforce the corners with extra stitching for added strength.

Once you have sewn the main body of the suitcase together, flip it right-side out and check for any loose threads or uneven stitching. Trim any excess threads and make adjustments if needed. Your suitcase is starting to take shape, but there are still more steps to complete. In the next section, we’ll cover how to add pockets and compartments to your custom suitcase.


Step 4: Adding Pockets and Compartments

Adding pockets and compartments to your suitcase can greatly enhance its functionality and organization. Follow these steps to incorporate them into your custom design:

  1. Design Placement: Determine where you want to add pockets and compartments to your suitcase. Consider the size and number of items you want to store in each pocket and choose suitable locations accordingly. Common options include interior pockets, exterior zippered compartments, or specialized compartments for shoes or toiletries.
  2. Cutting and Preparing the Fabric: Measure and cut the fabric pieces needed for each pocket or compartment according to your design. Make sure to add seam allowance to all sides. Additionally, interface any pieces that require extra stability and structure.
  3. Sewing Pockets: Pin the pocket fabric to the desired location on the main body of the suitcase, ensuring it aligns properly. Sew around the edges, leaving the top open for easy access. Reinforce the stitching at the corners and sides to provide strength and prevent fraying.
  4. Adding Compartments: For separate compartments, cut fabric panels that match the measurements of the main body of the suitcase. Sew these pieces onto the interior lining, dividing the space as desired. Consider adding zippers or other closures to keep the compartments secure.

Once you have added the pockets and compartments, take a moment to test their functionality and ensure they meet your needs. Adjustments can be made at this stage if necessary. The addition of these features will make your custom suitcase more versatile and efficient for your travel adventures.


In the next step, we will focus on attaching zippers and handles to complete the functional aspects of your suitcase.


Step 5: Attaching Zippers and Handles

Attaching zippers and handles to your custom suitcase is essential for easy access to your belongings and convenient transportation. Follow these steps to complete this important step:

  1. Zippers: Measure and cut the fabric pieces needed for the zipper openings. Ensure they match the dimensions of the zippers and provide sufficient seam allowance. Attach the fabric pieces to the edges of the opening where the zipper will be inserted.
  2. Prepare the Zippers: If necessary, trim the zippers to match the length of the openings. Fold the fabric edges over the zipper teeth, ensuring they are centered and aligned properly. Use pins or fabric glue to hold the fabric in place.
  3. Attach the Zippers: Stitch along the fabric edges to secure the zippers in place. Use a zipper foot attachment on your sewing machine to ensure accurate stitching close to the zipper teeth. Repeat this step for each zipper opening in your suitcase.
  4. Handles: Measure and cut the handle material to the desired length, keeping in mind the comfort and functionality of carrying the suitcase. Fold each end of the handle fabric inward to create a clean, finished edge. Secure the folds with pins or clips.
  5. Attach the Handles: Place the handle ends in the desired locations on the suitcase, ensuring they are centered and aligned symmetrically. Sew the handles securely onto the fabric, reinforcing the stitching for added strength.

Once you have attached the zippers and handles, test their functionality and durability. Make any necessary adjustments or reinforcements as needed. These additions will make your suitcase easy to open and close, as well as comfortable to carry or pull.


In the next step, we will focus on adding reinforcements and stabilizers to ensure the longevity of your custom suitcase.


Step 6: Adding Reinforcements and Stabilizers

To ensure the durability and longevity of your custom suitcase, it is important to add reinforcements and stabilizers at key areas. Follow these steps to strengthen your suitcase:

  1. Reinforce Corners and Stress Points: Identify the corners and other areas of the suitcase that may experience additional stress, such as the handle attachments or zipper ends. Cut small pieces of interfacing or stabilizer material and place them on the inside of the fabric at these points. Sew them in place to provide extra reinforcement.
  2. Stabilize the Interior: To give your suitcase more structure and stability, cut pieces of stabilizer material to match the dimensions of the main body and compartments. Sandwich them between the fabric layers and sew along the edges. This will help prevent sagging or collapsing and maintain the shape of your suitcase even when it’s empty.
  3. Add Bottom Stabilizers: To protect the bottom of your suitcase and provide support for heavy items, cut a piece of sturdy cardboard or plastic to match the dimensions of the bottom panel. Place it between the fabric layers and sew around the edges to secure it.
  4. Reinforce Handles: If desired, reinforce the handles by attaching additional layers of fabric or webbing to the underside for extra strength and durability. Stitch them securely in place, making sure to reinforce the attachment points.

By adding these reinforcements and stabilizers, your custom suitcase will be able to withstand the demands of travel and provide long-lasting performance. Take a moment to inspect and test these additions to ensure their effectiveness and make any necessary adjustments.


In the final step, we’ll cover the finishing touches and decorations that will make your suitcase uniquely yours.


Step 7: Finishing Touches and Decorations

Now that your custom suitcase is structurally complete, it’s time to add the finishing touches and decorations that will make it uniquely yours. Follow these steps to add those final details:

  1. Trim Excess Threads: Carefully go over your suitcase, trimming any excess threads or loose ends. This will give your suitcase a clean and polished appearance.
  2. Embroidery or Appliques: If you want to add a personal touch, consider adding embroidery or appliques to your suitcase. Choose designs that reflect your personality or travel theme. Use embroidery thread or iron-on appliques to attach the decorations securely.
  3. Personalized Tags or Labels: Attach a luggage tag or label with your name and contact information to make it easy to identify your suitcase in a crowded airport. Additional personalized labels or tags can also add a stylish element to your design.
  4. Decorative Patches or Ribbons: Enhance the visual appeal of your suitcase by adding decorative patches, ribbons, or trimmings. You can sew them onto the front, back, or sides of the suitcase for an extra pop of color and texture.
  5. Waterproofing or Protection: Consider spraying your suitcase with a waterproofing spray or applying a protective coating to ensure it can withstand unexpected weather conditions and potential spills during your travels.

These finishing touches and decorations will make your suitcase stand out from the crowd and reflect your unique style and personality. Take the time to carefully attach and secure any embellishments, ensuring they will withstand the rigors of travel.


With the completion of these steps, your customized suitcase is ready to accompany you on your next adventure. Enjoy the satisfaction of using a one-of-a-kind travel essential that perfectly suits your needs and reflects your individuality.


Now that you’ve mastered the art of making your own suitcase, you can create additional designs or share your newfound skills with others who are looking to embark on their own DIY travel projects.



Congratulations on completing the process of making your own custom suitcase! By following the steps outlined in this guide, you have created a functional, personalized, and durable travel essential that perfectly suits your needs and style.


From gathering materials and measuring the fabric to sewing the main body, attaching zippers and handles, and adding reinforcements and stabilizers, each step has contributed to the creation of a high-quality suitcase that can withstand the demands of travel. By incorporating pockets, compartments, and other features, you have enhanced the organization and functionality of your suitcase, making packing and accessing your belongings a breeze.


The finishing touches and decorations you added have given your suitcase a unique and personalized touch, ensuring it stands out in the crowd. Whether it’s embroidery, appliques, personalized tags, or decorative patches, these details reflect your personality and make your suitcase truly your own.


As you embark on your future travels, your custom suitcase will be a reliable companion, keeping your belongings safe and secure while showcasing your individuality. The pride and satisfaction you feel in using a handmade travel essential that perfectly suits your style and needs are truly rewarding.


Remember, the skills you’ve gained from this project can be applied to future DIY travel projects or shared with others who are interested in creating their own unique pieces. Your creativity and attention to detail have allowed you to create a custom suitcase that is not only functional but also a reflection of your personal style.


Now, pack your suitcase and embark on your next adventure with confidence and style!