Small hand luggage

Features

• side zip accessible laptop sleeve
• 3D-printed roll top hook
• carrying handle on the side
• stuff pockets and lots of elastic
• zippered front access pocket
• small Ryanair luggage compliant
• public domain licensed

Plans

• A4 tiled PDF
• A4 tiled SVG (Inkscape)
• raw DXF plans
• fabric layout
• Rhino 3D source model
• Rhino Grasshopper code used to create model

Dual channel 4mm linelock

• STL bevelled with Blender
• Solvespace CAD file

Learning and what I'd do different

• french seams are a great way to join bag pieces that avoids having to bind edges with tape
• single vertical pleat means stuff pockets taper too much at the bottom limiting their capacity
• taller stuff pockets = better stuff pockets
• taller rolltop part = better rolltop
• remember to insert all webbing loops to panels before joining panels
• Ryanair small size is tiny (but enough for a weekend)

Construction

Basic order of operations:

• make pockets
• attach pockets, webbing (I forgot those) and straps to sides
• laptop sleeve
  • tack back outer to side at top and bottom
  • insert side zip between tacks
  • attach back of sleeve to back of pack at zip seam
  • reinforce side panel lining with webbing
  • attach side lining and front of sleeve to other zip side
  • join side lining with side outer on remaining edges
  • attach handle to side pocket
  • attach webbing in between laptop sleeve parts (I forgot and it now is visible inside the pack)
  • complete laptop sleeve by stitching sleeve parts to back along bottom and side
    • attach other side panel to back
• front and bottom
  • sandwich both ends of pocket zip with outer and liner
  • attach outer and its lining to either side of the zip (could have sandwiched here to have it neater)
    • top stitch around zip
    • insert channel at top of inner pocket piece
    • attach pocket piece to front at bottom and sides
    • stitch through pocket piece and top of zip to create upper inner pocket
    • sandwich front panel with outer and lining of bottom
• join panels
  • left sides i.e. inners together stitch with a small seam allowance all around
  • turn back inside out and stitch at approx 1/4" to finish french seam
• finish back
  • insert back foam
  • stitch at top of back to close foam compartment
    • attach shoulder straps and handle, tacking through all back layers including webbing
• roll top
  • attach webbing to roll top back lining to to have a place for closure loop
  • create outer and lining loops by joining roll top backs to their front/side pieces
  • sandwich top of rest of back between outer and lining of roll top
  • fold up rolltop and topstitch
  • attach rolltop closure loop
  • attach webbing or plastic strip to front of roll top to ease rolling
  • enclose edges with tape