As practical as a material handling cart is, there are times when a fully loaded cart weighs too much to move without risk of injury. Common in large component industries, such as aerospace and heavy manufacturing, cart loads exceed 2,500 pounds, and caster performance, productivity, and safety become a concern as carts become more challenging to push or pull using a traditional caster configuration. In addition, initial push force requirements, tight spaces, the potential for overexertion injuries, and other challenges can diminish material handling effectiveness. This is where a motorized DRIVE CASTER® system can solve these issues effectively and cost-efficiently.

Conceptual Innovations invented the DRIVE CASTER®, an electric motor integrated with an industrial caster. Besides significantly reducing the force needed to move the cart, another significant benefit is that the DRIVE CASTER® system can be retrofitted to existing material handling carts. These motorized casters have weight capacities equivalent to an AGV at a lower cost.


With lower operating speeds and intuitive operation, operators do not need specialized training to use a drive-caster system. Employees can effortlessly move thousands of pounds of fixtures, finished goods, or production components with minimal exertion.

The DRIVE CASTER® features a ½-horsepower motor and eight-inch diameter wheels, AC and DC power options, and various control units. It can be used safely in any industry, from automotive to aerospace and ground support equipment. The DRIVE CASTER® technology can be easily added to a dolly, moving mall, turntable, platform, or other machinery to move up to 5,000 pounds per DRIVE CASTER®.

The customizable Drive Cart is another product developed by Conceptual Innovations utilizing a motorized drive. The Drive Cart can safely move up to 10,000 lbs. and is also equipped for long-distance transport. A switch or positioning of the tow hook quickly engages or disengages the motor. This feature allows utilization of the Drive Cart at higher speeds with a tugger or AGV. This makes manoeuvring from the tugger train to the work area easy, eliminating significant material transport constraints.

Our engineering team can design carts to meet existing specifications or retrofit the drive system caster technology onto existing carts, scaffolding, and other material handling platforms. We can fabricate carts with integrated electrical, hydraulic, and mechanical systems, ensuring the exact cart for your needs.