20251ME3: Folding Stair Climbing Trolley and Hand Truck

Brief Description & Functionality
A folding stair climbing trolley and hand truck is a mechanical device designed for safe and efficient transport of heavy goods over stairs and uneven terrain. The key feature of this device is the Tri-Star wheel mechanism, which allows the trolley to “walk” over steps. It is also equipped with a foldable steel frame, allowing the user to collapse and carry or store it conveniently when not in use.
This trolley is designed to:
- Climb standard staircases with minimal user effort
- Be folded for storage and easy portability
- Transport medium to heavy loads over uneven terrain
- Reduce physical strain on the operator compared to traditional trolleys
- Be built from low-cost, durable materials such as mild steel and rubber
Working Principle
The system integrates a Tri-Star wheel configuration, where three wheels are mounted on a rotating triangular frame on either side of the axle. When one wheel encounters an obstacle (like a stair edge), the frame rotates and positions the next wheel in contact, allowing the trolley to “climb” the step. This significantly reduces the lifting force required from the user.
Additionally, the foldable frame mechanism allows the trolley to be collapsed horizontally or vertically to reduce space consumption, making it ideal for compact storage in homes, warehouses, or delivery vehicles.

There are three possible design frames that are used to mount the tri-star wheels



Real-World Use Cases
- Delivery Logistics – For carrying parcels up residential stairs
- Warehousing – To lift boxes and materials across levels
- Retail and Hospitals – Where elevators are not always accessible
- Construction Sites – For manual transport of tools and materials
Market Survey


Useful Resources
https://www.slideshare.net/slideshow/stair-climbing-trolley/95260371#13
https://youtu.be/69_yLy1hBnQ?si=BEughj5WkAIO3Ar8
Skills Required
- 3D Printing FDM
- Welding
- Wood Working
- Drilling
- CAD Design
- Pipe bending
- Sheet bending