Custom Structural Dollies
Fully custom-engineered structural dollies for payloads, environments, and transport requirements that no catalog solution addresses. We begin with your load weight, dimensional envelope, locating requirements, and operating environment — and engineer the dolly structure, caster system, and interface features from those specific inputs.
Why Choose Modular Solutions for Custom Structural Dollies?
If your application doesn't fit a standard dolly, the right answer is a custom one — not a compromise that creates risk.
Engineering-First Design Process
Every custom structural dolly begins with an engineering review of the load requirements. Load weight, center of gravity, dimensional envelope, transport path, and docking interface are all documented before the first design decision is made. This prevents costly retrofits after fabrication.
Any Load, Any Configuration
Custom structural dollies are designed for loads from a few hundred pounds to tens of thousands of pounds. Frame construction ranges from standard 45 Series T-slot aluminum for lighter loads to steel-reinforced hybrid and all-steel primary construction for extreme payloads.
Environment-Specific Material Selection
Custom dollies for ESD-safe, cleanroom, washdown, food-grade, cryogenic, or outdoor environments are specified with materials, fasteners, casters, and surface finishes appropriate to the operating environment. No afterthought adaptations — environment requirements drive material selection from the beginning.
Custom Interface and Docking Features
Precision locating pins, docking receiver brackets, kinematic couplings, AGV interface features, height-adjustable platforms, and virtually any mechanical interface requirement can be engineered into the dolly frame as integral structural elements.
Drawing Package and Documentation
Custom dollies are delivered with engineering drawings, a load calculation summary, material certificates, caster load ratings, and lift point ratings. This documentation supports OSHA compliance, insurance audits, and internal safety reviews without additional engineering requests.
Repeat Orders Without Re-Engineering
Custom dolly designs are filed at Modular Solutions after first production. Repeat orders reference the existing drawings and ship at the standard four to six week lead time without re-engineering cost. Design revisions are handled as engineering change requests when load or interface requirements evolve.
Custom Engineering Capabilities
The full range of structural, mechanical, and environmental capabilities available for custom dolly design.
Multi-Material Frame Construction
Aluminum T-slot, steel-reinforced hybrid, all-steel primary, stainless steel cleanroom, and non-ferrous non-sparking designs are all available. Material selection is made based on load, environment, weight budget, and regulatory requirements of the specific application.
Precision Machined Interface Features
Where standard T-slot bracket-mounted locating pins are insufficient for the positional tolerance required, precision machined sub-plates and locating features are fabricated and integrated into the dolly structure. Tolerances to ±0.5mm positional accuracy are achievable with machined interface components.
Motorized Drive System Integration
Custom dollies can be integrated with electric motorized wheel systems, AGV interface receivers, and powered drive systems for applications where manual or tugger towing is not practical. Drive systems are selected and integrated based on the load weight, speed requirement, and positioning accuracy needed.
Active and Passive Isolation Systems
Vibration isolation systems for sensitive payload transport are available from simple isolation pad configurations to active pneumatic isolation platforms for precision instrument and semiconductor equipment transport applications.
Containment and Environmental Features
Battery containment trays, fire-retardant material options, fluid containment pans, and chemical-resistant surface treatments are available for dollies carrying hazardous or reactive payloads. These features are designed to meet applicable safety and environmental regulations.
Regulatory Compliance Support
Custom dollies for regulated industries including aerospace (AS9100), medical device (ISO 13485), food processing (USDA, FDA), and ESD (ANSI/ESD S20.20) are designed with the applicable compliance requirements built in. Documentation packages support customer qualification processes.
Example Custom Applications
Custom structural dollies have been engineered for applications including but not limited to the following categories.
- EV Battery Module Transport Dollies - Non-sparking aluminum frames with ESD-dissipative surfaces, format-specific cell position stops, and containment trays for thermal runaway management in battery pack assembly lines.
- Aerospace Structural Assembly Dollies - AS9100 FOD-controlled dollies for large aerospace structural subassemblies with precision datum locating features, captive fasteners, and material traceability documentation.
- Cryogenic Component Transport Dollies - Insulated structural dollies for transporting liquid nitrogen and liquid helium cooled components with stainless construction, sealed casters, and condensation management features.
- Large Optics and Mirror Transport - Precision vibration-isolated dollies for transporting large optical assemblies, telescope mirrors, and laser system components between fabrication and integration facilities.
- Nuclear Component Handling Dollies - Specially documented and material-traceable structural dollies for nuclear industry component handling with full material certification packages and quality inspection records.
- Automated Guided Vehicle Interface Platforms - Structural staging dollies designed to be picked up by AGV systems with precision docking receiver features that ensure repeatable load handoff between the dolly and the AGV carrier.
Custom Design Parameters
There are no standard dimensions for custom structural dollies — the following describes the design parameter space we work within.
| Parameter | Range / Options |
|---|---|
| Load Capacity | Any — from 200 lb to 50,000 lb and above with appropriate construction |
| Frame Material | T-slot aluminum, steel-reinforced hybrid, all-steel, stainless steel, or non-ferrous per requirement |
| Platform Dimensions | Any — designed to load envelope; no standard sizes for custom applications |
| Caster System | Any capacity, configuration, tread compound, and braking system; motorized drive available |
| Locating Features | Pins, V-blocks, nest pockets, kinematic couplings, precision machined sub-plates, AGV receivers |
| Environment | Standard, ESD, cleanroom, washdown, food-grade, cryogenic, outdoor, hazardous |
| Documentation | Engineering drawings, load calculations, material certs, compliance package per industry requirement |
| Lead Time | 8 to 12 weeks for new custom designs; 4 to 6 weeks for repeat orders on file designs |
Frequently Asked Questions
Common questions about custom structural dolly design from Modular Solutions.
What information do I need to provide to get a custom structural dolly designed?
To start a custom structural dolly design, we need the payload weight and center of gravity location, the load dimensional envelope, the floor surface type and condition, the transport path including doorways, ramps, and aisle widths, and any staging or docking interface requirements at the destination. If the load has specific locating datum requirements, fixture drawings or interface specifications are needed. The more information provided upfront, the faster our engineers can produce an accurate design proposal.
How long does the custom dolly engineering process take?
A preliminary design concept can typically be produced within one to two weeks of receiving the load requirements. Final engineering drawings for approval take an additional one to two weeks depending on the complexity of the locating features and structural analysis required. Once drawings are approved, fabrication lead time is four to six weeks. Total time from initial inquiry to delivery is typically eight to twelve weeks for complex custom designs.
Can custom dollies be designed for ESD, cleanroom, or other controlled environments?
Yes. Custom structural dollies can be designed for ESD-safe, cleanroom, washdown, food-grade, and other controlled environments. The frame, fasteners, casters, and deck surface are all selected for compatibility with the specific environment requirements. For ESD applications, dissipative surface paths and verified resistance specifications are designed in from the start. For cleanroom applications, sealed crevices, anodized surfaces, and non-particle-shedding materials are specified.
Are custom dollies available with integrated powered drive systems?
Yes. Custom structural dollies can be integrated with electric drive motor systems for applications where manual or tugger towing is not practical — extremely heavy loads, clean environments where exhaust tow vehicles are prohibited, or precision positioning applications where motorized drive allows fine position control. We work with drive system suppliers to integrate motorized wheel systems into the T-slot structural frame.
Can Modular Solutions produce repeat orders of the same custom dolly design?
Yes. Once a custom dolly design is approved and fabricated, the drawings are filed at Modular Solutions for repeat orders. Repeat production lead time returns to the standard four to six week window, and design costs are not repeated. If the load or interface requirements change between orders, we perform an engineering review to determine whether the existing design is still applicable or requires revision.
Ready to Describe Your Custom Dolly Requirement?
Tell us about your payload, your environment, and what the dolly needs to do. We'll propose a custom structural dolly design that addresses your specific application — not a generic solution adapted after the fact.
Modular Solutions — 4280 Giddings Rd, Auburn Hills, MI 48326