As practical as a material handling cart is, there are times when a fully loaded cart weighs too much to move manually. When cart loads exceed 2,500 pounds, they become 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 problems can keep a perfect cart from being utilized. This is where a motorized drive 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 different load-lifting requirements, operators do not need specialized training to use a drive-caster system. Employees can effortlessly move thousands of pounds of equipment 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 in any industry, from automotive to aerospace and ground support equipment. The Drive Caster can be easily added to a dolly, moving mall, turntable, platform, or other machinery to move up to 5,000 pounds.

The customizable Drive Cart is another product developed by Conceptual Innovations utilizing a motorized drive. The Drive Cart can 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 maneuvering 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 onto existing carts. We can fabricate carts with integrated electrical, hydraulic, and mechanical systems, ensuring the exact cart for your needs.