Choose aluminum when the case is the product: brand programs, overland use, lithium kits, anything over 20 kg of contents. Choose plastic when unit cost rules and the case is disposable packaging.
Rule of thumb: resold case = aluminum · tossed case = plastic
Aluminum case vs plastic case — a buyer’s comparison.
Both boxes close. What differs is what happens in year two.
The comparison that matters
| Factor | Aluminum case | Plastic case |
|---|---|---|
| Shelf & brand value | Premium look, laser/screen logo holds up | Molded-in graphics fade and date quickly |
| Heat & UV | Powder coat shrugs off sun; panel conduct heat but don’t warp | UV embrittles; latches creep in hot vans |
| Impact | Dents, still latches; corners scuff | Cracks at hinge points when cold |
| Weight | Heavier per liter at light classes | Lighter below ~20 L |
| Unit cost (light class) | Higher | Lower |
| Unit cost (heavy class) | Comparable — plastic must over-mold to match stiffness | Rises fast with size |
| Repairability | Latches, handles, panels replaceable | Usually whole-case replacement |
Where aluminum clearly wins
- Private-label tool kits — the box is part of the brand customers pay for.
- Overland and camping programs — UV, dust and rack vibration end plastic programs early.
- Lithium and equipment shipping — frame stiffness protects calibrated contents.
- Stacked warehouse storage — folding frames keep corners true under load.
Where plastic is the smarter buy
- Single-use export packaging where the case is discarded on arrival.
- Ultra-light consumer kits under 20 liters where every gram is marketing.
- Programs driven purely by lowest landed cost with no brand story.
The hybrid answer
Most of our distributor clients run both: aluminum cases for the branded kit SKUs, plastic for promotional bundles. If you want to test the water, the RC light classes are priced to trial — ask for a comparison quote with both options costed.