Airlines claim that they use reasonable care in handling checked luggage but I don't believe that one bit. In just one short flight from Chicago to Boston, my brand new spotless Tumi suitcase appeared on the luggage claim belt belly up, like a turtle on its back, with scuffs on the corners and dents in the plastic. Other parts of the ballistic nylon shell were frayed as if sandpaper was rubbed against it. I have started to seriously wonder how long any piece of luggage can last in today's travel environment.
Of course a major step to making your luggage last is to always carry your luggage on with you and avoid checking it in. Unfortunately, you won't be always able to do this (e.g. Abandon ye any hope on the small regional commuter planes).
This is where sail tape comes in handy. Sail tape is made in a variety of colors (include the all important color black) and a 2 inch wide 25 foot long roll will cost around 14 to 15 dollars [1]. You can also use the lighter spinnaker repair tape.
Why not just a cheap roll of duct tape? Sail tape comes with an adhesive backing that you peel away. This allows you to carry a thin strip of tape (instead of a bulky roll of duct tape) for repairs on the fly. Sail tape can be applied to damp surfaces (though it is best if the surface is clean and dry) and it is waterproof and flexible over the long term. It applies on smooth and can be permanent - but it can still be removed later if you so desire. Duct tape, on the other hand, doesn't adhere well to wet surfaces, becomes mucky around the edges and eventually gets brittle and starts to peel. Sail tape also has rip stop characteristics whereas you can rip duct tape easily with your hands along two axes.
So aside from repairing a tear in your luggage (apply the sail tape to both the inside and outside of the tear), perhaps the best application of sail tape is a proactive one. When the luggage is still brand new and the surfaces are clean and dry, use the sail tape to reinforce the areas you expect will get the most abuse from handling and the elements - this means the corners, the bottom area (when held upright) near the wheels, as well as any part that comes into contact with the ground when the luggage is in a natural resting position.
Note that at airports you might have limited access to scissors which you will need to cut sail tape. If you can't bring scissors with you and you can't borrow them from the airline officials pack a few pre-cut strips 3 to 4 inches long. Strips of those lengths will usually be enough to cover any tears.
[1] Bainbridge International Ripstop Nylon Tape sold at West Marine as of February 27, 2010. http://www.westmarine.com/webapp/wcs/stores/servlet/producte/10001/-1/10001/50843?&cid=chanintel&ci_src=14110944&ci_sku=50843.
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