Getting a typical 20" folding bike, like a Dahon, into an airline legal suitcase for travel obviously requires quite a bit of disassembly. I've now done this a couple of times and it is a bloody mess, not something I want to deal with repeatedly; adept bicycle mechanics may feel differently :-)
We all know that a Brompton, with its famous compact fold will go into such a suitcase without any disassembly, but how about a more "average" 16 incher, that doesn't fold as compactly? How much less disassembly is required to get such a bike into a "regular" suitcase, or a purpose built suitcase like an Airporter Mini? Looks to me as if at least the front wheel will need to come off, but I'm not sure.