Erin,
Which model do you have? I have the newest model, and for that I just stick it in its duffle that it came with along with all the cords, etc.... I use a luggage cart to transport it through the airport cause its still nearly 30 lbs. I always carry it on now.... Also, the TSA has said that anything you have to take as a carry on that is soley used for a disability (i.e. med equipment, meds, etc.) can NOT be counted against you as one of your carry on bags. Just an FYI. I've never been able to take more than that and a purse anyway cause I just can't handle all that by myself, but it is allowed.
If you have the larger version of the vest, I also used the luggage cart to tote that around the airport and carried it on... Or, a couple times, I also did box it in a big huge box that the company sent me for flying (when I called and requested it), and checked it. The box is supposed to have enough padding to protect it en route. I also wrote in big yellow medical stickers... FRAGILE MEDICAL EQUIPMENT all over the box. So, you can either carry it on (although it may not fit in some overhead bins, so you may want to have the dimensions and call in advance to make sure) or you can have the vest company send you a big box to check it.
Good luck! I know its daunting at first, but I fly alone with mine all the time now, and it goes pretty smoothly.
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