Fill the carry-on suitcase until the contents reach almost to the top of the bag. This is the key to preventing roller bar marks on your suit. First, use smaller items, such as underwear and socks, to act as padding around the roller bars. This gives the subsequently packed layers of clothing a flat surface on which to perch. Ensure that the contents create a flat surface, ending 2 inches below the zipper line. This is because movement inside the case will create wrinkles, and keeping the bag tightly packed is the only way to keep the suit from shifting during travel.
Position the suitcase so that it sits horizontally in front of you, with the widest edges at the top and bottom. Place the shoulders of the suit jacket inside the suitcase, bringing the collar right up to the upper edge.
Button the suit jacket and fold the arms across the front. They should create a V shape when positioned correctly.
Fold the trousers so that they are on their side with the front and back creases matching. Place the suit trousers perpendicularly over the top of the suit jacket, drawing the waistband over to lie flush against one of the the suitcase's narrow edges. The lower half of the trouser legs should be lying outside the suitcase.
Fold the hem of the suit jacket up to meet the collar. Ensure that there are no wrinkles in the fabric as you do this. At this point, the suit jacket will be neatly tucked into the suitcase. If your suit is made of a fabric that is not prone to wrinkling, such as worsted wool, the padding from the trousers, which separates the two layers of the suit, will be enough to keep the garment from wrinkling. However, if your suit is made of a wrinkle-prone fabric such as linen, place rolled items such as underwear inside the folds to ensure that the folds are not sharp, decreasing the possibility of wrinkling.
Fold the lower half of the trouser legs over the top of the suit jacket. This will ensure that the entire suit is folded neatly inside the suitcase. In this way, the jacket and trousers protect each other, ensuring that they do not wrinkle during your trip.
Zip up the suitcase without placing any additional items on top of the suit.
