Journalist Picks 5 Best Carry-Ons After Testing 15 Suitcases

Q: What hidden airline policy could force your meticulously chosen TSA-approved carry-on into the cargo hold anyway?

Even a TSA-size-compliant carry-on can be forced into the hold under airlines’ overhead-bin management policies, especially on regional jets or when agents predict bin space will run out. The key hidden rule is that compliance with the standard 22 x 14 x 9 inch limit does not guarantee cabin access. Airlines may require gate-checking when overhead bins are expected to fill, when the aircraft is smaller, or simply to speed boarding and protect an on-time departure. Reporting from recent passenger complaints and airline responses shows some carriers use predictive formulas or “optimization tools,” based on aircraft type, load, and past baggage patterns, to decide before bins are actually full. That means your bag can be taken even if it would physically fit and even if empty bin space remains once you board. This is especially common on regional aircraft, where gate agents may proactively remove roll-aboards from later boarding groups. There is another less obvious checkpoint issue too: TSA’s newer CT scanners have smaller openings than older machines. A bag that is technically airline-compliant but overstuffed or expanded may not fit through the scanner and could then have to be checked with the airline. If the bag is gate-checked because bin space is unavailable, that is usually free. If it is checked because it exceeds the airline’s size allowance or your fare does not permit a full carry-on, standard checked-bag fees can apply.

3 articles · Updated · The Guardian · Oct 16

Fifteen carry-on models from 10 brands were tested, with Cotopaxi’s $295 Coraza named best overall for its removable liners, replaceable parts and lifetime warranty.
The shortlist split by use case: Heys Airlite at $180 won best budget, Away’s $225 Softside led softside picks, the $205 Softside Compact topped overnighters, and Peak Design’s $600 Roller Pro was the splurge choice.
Testing focused on bags near the 22 x 14 x 9-inch TSA carry-on standard, then finalists were taken on real trips to judge airport handling and overhead-bin fit.
The guide argues carry-ons can avoid checked-bag fees of $50 or more, save baggage-claim time and reduce the risk of lost luggage, while durability still matters because gate-checking remains common.