A gate check can ruin your whole rhythm, especially when it’s a tiny regional jet, a snowstorm, and your jacket is trapped inside your suitcase. We’re talking with Dave Logan of Only Travel about the moment a freezing wait on the tarmac in Sioux Falls turned into a serious design mission: build a modular carry-on system that helps travelers avoid checking bags and move through airports faster.

OnliTravel.com

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Check out Onli Travel's latest review: https://www.yankodesign.com/2026/05/05/this-214-modular-backpack-system-zips-apart-into-3-separate-bags-youll-actually-want-to-use/

We get practical about what makes travel stressful and what actually fixes it. Dave breaks down the Trilogy Modular System, a three-part modular luggage setup that combines a four-wheel rolling spinner with attachable bags you can zip together or split apart depending on the trip. We also dig into real-world airline constraints, like why many “standard” carry-on spinners are built to the maximum size yet still fail under-seat fit, and how designing at eight inches deep can create a crucial backup option when overhead bins fill up.

Then we zoom in on the packing process itself: labeled packing cubes that work like a packing checklist, quick access for TSA 3-1-1 liquids, cords and chargers organization, clean and dirty separation, and features that help reduce wrinkles. Dave also shares the behind-the-scenes reality of product innovation: prototypes, patents, beta testing across the world, COVID-era design challenges, fabric selection, and even zipper tensile-strength testing with YKK.

If you care about smart travel gear, carry-on packing tips, and building a flexible “roam to home” lifestyle, you’ll take away ideas you can use immediately. Subscribe, leave a review, and share this with a friend who’s tired of baggage claim. What’s the one luggage feature you wish existed?

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