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High-Speed Outdoor Tugging Casters for Heavy Automotive Manufacturing

Solid Rubber Wheel web

As automotive manufacturing evolves, so do the demands placed on material handling equipment. Larger components, faster production cycles, and expansive facilities require mobility solutions that can safely move extreme loads at higher speeds — often outdoors and under tight deadlines. In this case study, Caster Connection partnered with a major electric vehicle manufacturer to design and deliver a high-speed outdoor tugging caster solution for transporting 7,000-lb gigacast components across a large production campus. The application required a rare combination of speed, load capacity, durability, and rapid execution, all while minimizing risk to production schedules.

The Challenge: Heavy Loads, High Speed, Outdoor Travel

The manufacturer needed to move large structural castings from the casting department to an outdoor storage area, then tug those same loads nearly a mile around the plant to final assembly.

This application introduced multiple compounding challenges:

  • Load requirement: 7,000 lbs per cart

  • Travel speed: Up to 15 mph

  • Environment: Outdoor use with exposure to weather and surface variation

  • Distance: Long, repeated routes around a large manufacturing facility

  • Component sensitivity: Smooth transport was critical to protect high-value parts

  • Timeline: A non-negotiable deadline tied directly to production readiness

Any delay would have impacted downstream assembly operations.

The Solution: Engineered Casters for High-Speed Outdoor Tugging

Caster Connection recommended a 2 swivel / 2 rigid caster configuration using a 16 × 5 solid rubber wheel, engineered specifically for high-speed, heavy-duty applications.

Why This Solution Was Selected

High-Speed Load Capacity

  • Each 16 × 5 solid rubber wheel is rated at 3,400 lbs at 15 mph

  • The configuration comfortably supported the full 7,000-lb load while maintaining stability during towing

Outdoor Durability with Smooth Ride Quality

  • Solid rubber construction withstands outdoor conditions and debris

  • Delivers a controlled, smooth ride, reducing vibration and protecting large cast components during transport

Custom Hub & Integration Engineering

  • The wheels were supplied independently rather than as a standard caster assembly

  • Caster Connection engineers designed a custom hub to integrate the wheels into the customer’s existing fork and spindle design

  • Each hub was hand-fit, tested, and assembled to ensure proper alignment and performance

Optimized Caster Configuration

  • Two swivel casters for maneuverability during positioning

  • Two rigid casters for straight-line tracking and stability at speed

  • Ideal balance for long-distance outdoor tugging

Results

The Results: Reliability, Speed, and Cost Savings

  • Successful operation at up to 15 mph with 7,000-lb loads
  • Over 50% cost savings compared to the original supplier quote
  • In continuous operation since July 2021, performing reliably in demanding conditions
  • Only one isolated issue, traced to variables in the cart, tongue, and hitch design — not the casters

(Caster Connection proactively connected the customer with a trusted fabrication partner to address the system-level issue)

  • Replacement casters stocked on-site to reduce risk of downtime
Hour glass

When the Deadline Couldn’t Move, We Did

As the deadline approached, global shipping delays threatened to derail the project. With production at risk, the Caster Connection team took extraordinary action.

The casters were assembled, tested, and personally driven 18 hours directly to the manufacturing facility to ensure the carts were operational on time. Each assembly weighed close to 90 lbs, requiring coordinated, hands-on effort from multiple team members.

It was a clear example of Caster Connection’s commitment: when manufacturing can’t wait, neither do we.

Magnifying Glass

Why This Case Study Matters

This project demonstrates Caster Connection’s ability to support:

  • High-speed caster and wheel applications
  • Heavy-duty outdoor material handling
  • Custom caster and wheel engineering
  • Automotive and advanced manufacturing environments
  • Downtime prevention through proactive design and on-site stocking

When off-the-shelf solutions aren’t enough, Caster Connection engineers mobility systems built around real-world demands.

Need a High-Speed or Heavy-Duty Caster Solution?

If you’re moving heavy loads at speed — indoors or outdoors — our engineering team can help you design a solution that protects your people, your products, and your production schedule.

Start with a Caster Needs Evaluation to connect with a caster expert and get a mobility solution tailored to your application.

Need a High-Speed or Heavy-Duty Caster Solution?