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I’ve used a Tumi aluminum suitcase, ultralight, no flex. A Dell 24” 4K monitor and other dev gear fits perfectly. Since it doesn’t flex you don’t need to pack very well, just a few clothes to stop movement. Example photos:

https://www.dropbox.com/sh/jjxctk02nvb5wmy/AADnscpr1HQCFZeiO...

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What about the weight? For flight travel to work it needs to be way under 23kg.

The suitcase is only 6.4 kilos, it's really light for what it does. It's just a thin shell basically. Monitor is 4 kilos. That leaves a bunch of room for other stuff. You don't have to use any of the packing material since it's so stiff, that helps a lot.

do you mind sharing the details of your whole setup? i/e laptop, laptop stand, keyboard, mouse etc? looks great.

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