Horizontal Trolley Design for Paint Line
Client: EPTEC – Government & Defence Contractor
EPTEC, a leading Australian contractor in government and defence maintenance, approached Applied Project to resolve critical inefficiencies in their defence-grade paint line. Their existing equipment lacked mobility, consumed valuable floor space, and struggled to accommodate a wide variety of bulky, irregularly shaped components.
Our brief was clear: design a robust, space-efficient horizontal trolley system that enhances throughput, boosts safety, and integrates seamlessly into EPTEC’s demanding workflow.
Challenge
Defence products pose unique handling challenges—heavy, awkward forms, specialised coatings, and tight quality requirements. EPTEC needed a trolley that could:
Carry substantial loads without flexing
Accommodate varying shapes and sizes
Improve mobility in a congested workshop
Reduce footprint when not in use
Withstand aggressive industrial environments
Their existing setup contributed to bottlenecks and floor-space restrictions that hindered productivity. The solution required both heavy-duty engineering and smart functional design.
Approach
We began with a detailed review of EPTEC’s operational workflow, material handling practices, and space allocation. Mapping out their process helped us pinpoint pain points and prioritise features that would deliver immediate value.
From there, we explored concepts through sketches and 3D CAD models, iterating toward a trolley design that balanced strength, practicality, and adaptability.
Design Solution
Structural Frame
A rugged rectangular chassis constructed from steel or aluminium RHS beams, finished in military-spec green. The welded frame maximises rigidity under load, while the open-design platform reduces weight and improves air circulation during coating processes.
Platform size: approx. 1.5 m (L) × 0.6 m (W)
Height: approx. 0.8 m
Frame: longitudinal & transverse beam grid for stability
Bracing: diagonal corner reinforcements to eliminate twist
Mobility & Handling
Engineered for smooth, controlled movement within a busy workshop:
Four fixed caster wheels
Wheel size: 100–150 mm diameter
Load rating: 200–300 kg each
Optional base plates for floor anchoring when required
This setup ensures predictable travel paths, ideal for paint line repeatability and operator safety.
Advanced Features (Concept Options)
To future-proof the design and elevate usability, we explored several enhancements:
Adjustable supports for variable component sizes
Rotating top platform for 360° access during coating
LED task lighting for improved surface visibility
Tool hooks and accessory rails
Collapsible or stackable frames for maximum floor-space efficiency
These modular options allow EPTEC to tailor the trolley to different defence manufacturing needs.
Outcome
Although the project paused due to budget constraints and stakeholder timing, the development process delivered EPTEC:
A validated mechanical concept ready for implementation
Insight into workflow inefficiencies and process improvements
A scalable trolley platform that can be revived or adapted for future programs
For Applied Project, the outcome showcases our ability to deliver high-performance mechanical design solutions grounded in practical industry needs—combining engineering precision with innovative thinking.
This project highlights our capability in designing specialised mechanical equipment for defence and industrial environments. Even when projects pause, our clients walk away with clarity, direction, and engineered solutions that set them up for future success.
Need Engineering & Drafting Support?
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Contact Applied Project today to explore how we can collaborate on your next venture.