Folding Cart Evolution

The Evolution of Our Folding Cart

Every great product starts with a real problem.

For us, it began with a friend — a lighting design engineer working on set and at live events. He needed a folding cart that could transport equipment easily, pack down compactly, and withstand the demands of professional use. That first request sparked what would eventually become Hippo Carts.

Version 1: The Starting Point

Our first cart was built with functionality in mind. Constructed from aluminium, it folded down to a compact 850mm × 650mm × 150mm, making it easy to transport and store. It featured sliding lock wheels, carpeted trays, two levels, a folding ledge, and vertical stable storage.

It worked — but not perfectly.

We quickly identified key issues:

• Lack of rigidity
• Overly complex design
• Drag wheels that didn’t move smoothly
• Heavy reliance on overseas suppliers

It was a strong concept, but it needed refinement.

Version 2: Refinement & Local Production

With Version 2, we focused on simplification and control.

We reduced the number of components, moved to full UK fabrication, improved the drag wheels, and introduced bolt-on stiffener rails to increase strength.

But new challenges emerged:

• Incorrect aluminium grade led to poor bend quality
• Folding mechanism felt clunky
• Lid fit was too tight, making pack-down difficult
• Folding ledge weakened overall structure
• Costs increased due to design complexity
• 3D-printed parts failed under stress testing

This version taught us an important lesson: simplicity and material choice are everything.

Version 3: The Final Design

Version 3 is where everything came together.

We switched to Aluminium 1050, allowing for clean, precise bends. The folding ledge was removed to create a sleeker, stronger structure, and the cart was redesigned with a fully welded aluminium chassis.

Key improvements included:

• A smooth, quick folding mechanism with upgraded hinges
• Fewer components for increased reliability and lower cost
• Improved wheels for effortless movement
• A cleaner, more robust overall design
• Design kept simple to keep costs low (aim is to be under £1000)

This is the version that truly represents what Hippo Carts stands for, practical, durable, and purpose built.

The first unit is being built now and will be ready by the end of April.

Follow us on Instagram to see the cart come to life and be the first to hear about pre sales.

We’ll be showcasing the cart publicly for the first time at MPTS 2026 in London on May 13th 2026.

Looking Ahead

We’re not stopping here.

Our next goal is to expand the range with two size options, including a compact version designed to meet airline luggage requirements. The aim is simple: give professionals a reliable cart they can take anywhere.

From a single request to a refined product, this journey has been all about solving real problems through iteration, learning, and constant improvement.