Zero Halliburton

—Reimagining an American travel case icon

Brief

Premium aluminum travel case line designed for modern travellers. Zero Halliburton is an iconic premium American luggage brand that pioneered aluminum travel cases in the 1930s and built its authentic heritage and legacy with quality craftsmanship, resilience, and durability. Pensa was commissioned to modernize Zero Halliburton's attaché and luggage lines, with a focus on enhancing their durability and user experience for the modern traveler. As Zero Halliburton is well-known for its clean and sculptural mid-century aesthetics, we aimed to build upon the brand's 80-year heritage while bringing a fresh perspective to the new line. Result is a bold modernization of an iconic brand.

Designed at Pensa

Client: Zero Halliburton

Role: Industrial Designer

Year: 2022

Team Credits:  Peter Chung, Mark Prommel, Marco Perry

Brand Heritage: An ad from the 1940s, ZH classic atache and travel cases, Inception movie poster

Approach

Fusing brand story into luxurious travel experience. We took a two-day trip from NYC to Chicago to go through a full travel experience to uncover design opportunities.

Concave edge

Unlike molded plastic shells, an aluminum case is a formed object with both possibilities and limitations. Our objective was to push the boundaries and leverage the material qualities to create a stronger and more structurally sound case with a beautiful, iconic, and sculptural form. Through rigorous testing of various geometries, we discovered that a concave edge significantly outperformed traditional bent or rounded geometries when absorbing and protecting against impacts. The form that runs along the edges serves not only a functional purpose but also adds an elegant and distinctive signature element to all cases in the collection.

Plastic chasis

Unlike typical wheel wells in hard sided luggage, we incorporated one-piece, fully integrated, reinforced bases which provide protection to the entire lower portion of the shells and the wheel areas, while adding to the distinct look.

Pull handle

The retractable pull handle is designed for comfort and ease of grip, rather than conforming to the shape of the case. That contrast along with the high-glossy material accentuate the luxurious and comfort aspect of the handle.

Lock & name tag

Cushion-cut latch locks are built for elegance and robust security.  The integrated magnetized leather ID cover sits flush with the luggage body, and the leather can be etched with initials.

Interior design & accessories

The case's exterior is crafted with robust construction and sturdy materials to ensure reliable protection, while its interior offers a gentle touch that provides delicate care for your belongings. The thoughtfully designed interior space offers a spacious and intuitive packing experience, enhanced by add-on accessories like packing cubes, a garment sleeve, and a retractable hanger.

The garment sleeve enables a wrinkle-free packing experience due to its cushioned construction. When pulled from the leather tab, the retractable hangers minimize their footprint within the case. Furthermore, packing cubes help you to organize a wide range of items, from delicate articles to bulkier pieces.

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