Creating NWL cart

Our first step was to determine the total weight of the required components, survey the future battle grounds, and analyze client’s feedback from prior years of use of the expensive, all metal, boxy predecessor. Having determined the carrying loads of the top and bottom parts of the cart we sketched out several ways of connecting them. The size, material and positioning of the fixed and turning wheels was determined by the need to easily roll over cables, wires, and thresholds.

In order to achieve the smallest footprint possible we analyzed over 125 various arrangements of components inside the base. Each element in the system was thoroughly analyzed from the weight, size and function standpoint. We took into account such aspects as base stability, visibility of battery charge indicators, accessibility of the inverter’s shut-off switch and heat emission characteristics of each element to prevent overheating.

Concurrent with first visualizations of the cart a process of material selection was underway. The construction had to be rigid, base needed to be heavy to prevent tipping over, external elements had to be durable, yet the whole design had to be elegant and lightweight. A winning combination of wire concealing main metal support tube, metal base chassis, plastic covers and acrylic top was achieved.

In building of the first prototypes we turned to a company manufacturing fixed wing sport planes, industry synonymous with composite material construction, reliability, weight constraints and overall look importance.