A hand trolley, also known as a hand truck, is a small, wheeled cart with a weldment frame, used to move heavy or bulky items over short distances. It's essentially a simple lever system that makes lifting and moving objects much easier

// Hand Trolley
// A hand trolley, also known as a hand truck, is a small, wheeled cart with a weldment frame, used to move heavy or bulky items over short distances. It's essentially a simple lever system that makes lifting and moving objects much easier
// Categories: Manufacturing, Construction

// Set units
@settings(defaultLengthUnit = in)

// Import parameters
import * from "parameters.kcl"
import "wheel.kcl" as wheel
import "weldment.kcl" as weldment

import "axle.kcl" as axle
wheel
  |> patternCircular3d(instances = 2, axis = [0, 0, 1], center = [0, -3.67, 0])


// Hand Trolley Axle

// Set units
@settings(defaultLengthUnit = in)

// Import parameters
import * from "parameters.kcl"

// Model the lifting grate as a sheet metal part
grate = startSketchOn(-YZ)
  |> startProfile(at = [-grateDepth, 0])
  |> yLine(length = grateThickness, tag = $seg11)
  |> xLine(endAbsolute = tubeDiameter)
  |> tangentialArc(angle = 90deg, radius = bendRadius)
  |> yLine(length = 1.5, tag = $seg01)
  |> xLine(length = grateThickness, tag = $seg10)
  |> yLine(length = -segLen(seg01))
  |> tangentialArc(angle = -90deg, radius = bendRadius + grateThickness)
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
  |> extrude(
       length = frameWidth + tubeDiameter,
       symmetric = true,
       tagStart = $capStart001,
       tagEnd = $capEnd001,
     )
  |> fillet(
       radius = 1,
       tags = [
         getCommonEdge(faces = [seg10, capStart001]),
         getCommonEdge(faces = [seg11, capEnd001]),
         getCommonEdge(faces = [seg10, capEnd001]),
         getCommonEdge(faces = [seg11, capStart001])
       ],
     )

// Model the path of the outer rail of the trolley frame
outerRail = startSketchOn(offsetPlane(XZ, offset = tubeDiameter / 2))
  |> startProfile(at = [-frameWidth / 2, grateThickness])
  |> yLine(endAbsolute = height - tubeBend)
  |> tangentialArc(angle = -90deg, radius = tubeBend)
  |> xLine(endAbsolute = 0, tag = $seg02)
  |> xLine(length = segLen(seg02))
  |> tangentialArc(angle = -90deg, radius = tubeBend)
  |> yLine(endAbsolute = profileStartY())

// Sweep the tube profile around the outer rail path to give it a thickness
outerRailThicken = startSketchOn(offsetPlane(XY, offset = grateThickness))
  |> circle(center = [-frameWidth / 2, -tubeDiameter / 2], diameter = tubeDiameter)
  |> sweep(path = outerRail)

// The minimum allowable straight length should equal double the bend radius
centerRail = startSketchOn(YZ)
  |> startProfile(at = [-tubeDiameter / 2, grateThickness])
  |> yLine(length = tubeBend * 2)
  |> tangentialArc(angle = 30deg, radius = tubeBend, tag = $seg03)
  |> angledLine(angle = tangentToEnd(seg03), length = tubeBend * 2)
  |> tangentialArc(angle = -30deg, radius = tubeBend, tag = $seg04)
  |> angledLine(angle = tangentToEnd(seg04), endAbsoluteY = height - (tubeBend * 3.835), tag = $seg27)
  |> tangentialArc(angle = 45deg, radius = tubeBend, tag = $seg05)
  |> angledLine(angle = tangentToEnd(seg05), length = tubeBend * 2)
  |> tangentialArc(angle = -135deg, radius = tubeBend, tag = $seg06)
  |> angledLine(angle = tangentToEnd(seg06), endAbsoluteX = -tubeDiameter / 2)

// Sweep the tube profile around the center rail path to give it a thickness
centerRailThicken = startSketchOn(XY)
  |> circle(center = [0, -tubeDiameter / 2], diameter = tubeDiameter)
  |> sweep(path = centerRail)

// Model supporting ribs for the trolley frame
rib = startSketchOn(offsetPlane(XY, offset = 14))
  |> startProfile(at = [
       -(frameWidth - tubeDiameter) / 2 - .05,
       -.6
     ])
  |> arc(interiorAbsolute = [0, -3.15], endAbsolute = [-profileStartX(), profileStartY()], tag = $seg14)
  |> angledLine(angle = tangentToEnd(seg14) + 90, length = grateThickness)
  |> arc(interiorAbsolute = [0, -3.15 + grateThickness], endAbsolute = [-lastSegX(), lastSegY()])
  |> line(endAbsolute = [profileStartX(), profileStartY()])
  |> close()
  |> extrude(length = 1)
  |> patternLinear3d(instances = 3, distance = segLen(seg27) / 3, axis = [0, 0, 1])

// Create welded brackets to support the axle
brackets = startSketchOn(offsetPlane(YZ, offset = frameWidth / 2))
  |> startProfile(at = [-tubeDiameter, wheelDiameter / 2 - 3])
  |> yLine(length = 0.54, tag = $seg16)
  |> tangentialArc(angle = 60deg, radius = bendRadius, tag = $seg07)
  |> angledLine(angle = tangentToEnd(seg07), length = 2.58, tag = $seg15)
  |> tangentialArc(angle = -90deg, radius = bendRadius + grateThickness)
  |> tangentialArc(angle = 60deg, radius = 1.5)
  |> tangentialArc(angle = -90deg, radius = bendRadius + grateThickness, tag = $seg08)
  |> angledLine(angle = tangentToEnd(seg08), length = segLen(seg15))
  |> tangentialArc(angle = 60deg, radius = bendRadius, tag = $seg09)
  |> yLine(length = segLen(seg16))
  |> xLine(length = grateThickness)
  |> yLine(length = -segLen(seg16))
  |> tangentialArc(angle = -60deg, radius = bendRadius + grateThickness, tag = $seg17)
  |> angledLine(angle = tangentToEnd(seg17), length = segLen(seg15))
  |> tangentialArc(angle = 90deg, radius = bendRadius)
  |> tangentialArc(angle = -60deg, radius = 1.5 + grateThickness)
  |> tangentialArc(angle = 90deg, radius = bendRadius, tag = $seg18)
  |> angledLine(angle = tangentToEnd(seg18), length = segLen(seg15))
  |> tangentialArc(angle = -60deg, radius = bendRadius + grateThickness, tag = $seg19)
  |> yLine(length = -segLen(seg16))
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
  |> extrude(length = 0.75 * tubeDiameter, symmetric = true)

// Model a bearing for the axle on each bracket
axlebearing = startSketchOn(offsetPlane(YZ, offset = frameWidth / 2))
  |> circle(center = [-3.67, wheelDiameter / 2], diameter = 1)
  |> subtract2d(tool = circle(center = [-3.67, wheelDiameter / 2], diameter = .75))
  |> extrude(length = tubeDiameter, symmetric = true)

patternLinear3d(
  [brackets, axlebearing],
  instances = 2,
  distance = frameWidth,
  axis = [-1, 0, 0],
)

axle = startSketchOn(-YZ)
  |> circle(center = [3.67, wheelDiameter / 2], diameter = 0.75)
  |> extrude(length = frameWidth + 4, symmetric = true)

// Revolve a wheel that mounts to the trolley axle
wheel = startSketchOn(offsetPlane(XY, offset = wheelDiameter / 2))
  |> startProfile(at = [
       -frameWidth / 2 - 0.65,
       -3.67 + 0.75 / 2
     ])
  |> xLine(length = -2.7)
  |> yLine(endAbsolute = -3.67)
  |> xLine(length = -0.5)
  |> yLine(length = 0.44)
  |> tangentialArc(angle = -85deg, radius = 0.2, tag = $seg21)
  |> angledLine(angle = tangentToEnd(seg21), length = 1.14)
  |> tangentialArc(angle = 85deg, radius = 0.1, tag = $seg22)
  |> angledLine(angle = tangentToEnd(seg22), length = 1.28)
  |> tangentialArc(angle = 85deg, radius = 0.1, tag = $seg23)
  |> angledLine(angle = tangentToEnd(seg23), length = 0.95)
  |> tangentialArc(angle = -80deg, radius = 0.2, tag = $seg24)
  |> angledLine(angle = tangentToEnd(seg24), length = 0.77)
  |> xLine(length = 0.15)
  |> angledLine(angle = tangentToEnd(seg24), length = -0.7)
  |> xLine(length = 2)
  |> angledLine(angle = -tangentToEnd(seg24), length = -0.7)
  |> xLine(length = 0.12)
  |> angledLine(angle = -tangentToEnd(seg24), length = 0.77)
  |> tangentialArc(angle = -80deg, radius = 0.2, tag = $seg25)
  |> angledLine(angle = tangentToEnd(seg25), length = 0.43)
  |> tangentialArc(angle = 85deg, radius = 0.1)
  |> yLine(length = -0.91)
  |> tangentialArc(angle = 85deg, radius = 0.1)
  |> angledLine(angle = -tangentToEnd(seg25), endAbsoluteX = profileStartX())
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
  |> revolve(axis = {
       direction = [1.0, 0.0],
       origin = [0.0, -3.67]
     })

tire = startSketchOn(offsetPlane(XY, offset = wheelDiameter / 2))
  |> startProfile(at = [-frameWidth / 2 - 3.55, -1.05])
  |> angledLine(angle = 100, length = 0.73, tag = $seg26)
  |> tangentialArc(endAbsolute = [lastSegX(), wheelDiameter / 2.1 - 3.67])
  |> tangentialArc(angle = 10deg, radius = 1)
  |> tangentialArc(angle = -90deg, radius = wheelDiameter / 100, tag = $seg12)
  |> angledLine(angle = tangentToEnd(seg12), length = 2.25)
  |> tangentialArc(angle = -90deg, radius = wheelDiameter / 100)
  |> tangentialArc(angle = 10deg, radius = 1)
  |> tangentialArc(endAbsolute = [lastSegX(), segEndY(seg26)], tag = $seg13)
  |> angledLine(angle = -100deg, length = segLen(seg26))
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
  |> revolve(axis = {
       direction = [1.0, 0.0],
       origin = [0.0, -3.67]
     })
  |> appearance(color = "#010101", metalness = 10, roughness = 70)

patternCircular3d(
  [wheel, tire],
  instances = 2,
  axis = [0, 0, 1],
  center = [0, -3.67, 0],
)

appearance(
  [
    grate,
    brackets,
    axlebearing,
    outerRailThicken,
    centerRailThicken,
    rib,
    wheel
  ],
  color,
  metalness = 40,
  roughness,
)


// Parameters for Hand Trolley

// Set units
@settings(defaultLengthUnit = in)

// Define parameters
export frameWidth = 20
export tubeDiameter = 1
export height = 51
export grateDepth = 10
export grateThickness = 0.090
export wheelDiameter = 10
export color = "#c00c0c"
export metalness = 40
export roughness = 30

// Calculate stock material bend radii
export tubeBend = tubeDiameter * 2.5
export bendRadius = grateThickness * 1.25


// Hand Trolley Weldment
// A weldment is a frame constructed from welded metal pieces

// Set units
@settings(defaultLengthUnit = in)

// Import parameters
import * from "parameters.kcl"

// Model the lifting grate as a sheet metal part
grate = startSketchOn(-YZ)
  |> startProfile(at = [-grateDepth, 0])
  |> yLine(length = grateThickness, tag = $seg11)
  |> xLine(endAbsolute = tubeDiameter)
  |> tangentialArc(angle = 90deg, radius = bendRadius)
  |> yLine(length = 1.5, tag = $seg01)
  |> xLine(length = grateThickness, tag = $seg10)
  |> yLine(length = -segLen(seg01))
  |> tangentialArc(angle = -90deg, radius = bendRadius + grateThickness)
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
  |> extrude(
       length = frameWidth + tubeDiameter,
       symmetric = true,
       tagStart = $capStart001,
       tagEnd = $capEnd001,
     )
  |> fillet(
       radius = 1,
       tags = [
         getCommonEdge(faces = [seg10, capStart001]),
         getCommonEdge(faces = [seg11, capEnd001]),
         getCommonEdge(faces = [seg10, capEnd001]),
         getCommonEdge(faces = [seg11, capStart001])
       ],
     )

// Model the path of the outer rail of the trolley frame
outerRail = startSketchOn(offsetPlane(XZ, offset = tubeDiameter / 2))
  |> startProfile(at = [-frameWidth / 2, grateThickness])
  |> yLine(endAbsolute = height - tubeBend)
  |> tangentialArc(angle = -90deg, radius = tubeBend)
  |> xLine(endAbsolute = 0, tag = $seg02)
  |> xLine(length = segLen(seg02))
  |> tangentialArc(angle = -90deg, radius = tubeBend)
  |> yLine(endAbsolute = profileStartY())

// Sweep the tube profile around the outer rail path to give it a thickness
outerRailThicken = startSketchOn(offsetPlane(XY, offset = grateThickness))
  |> circle(center = [-frameWidth / 2, -tubeDiameter / 2], diameter = tubeDiameter)
  |> sweep(path = outerRail)

// The minimum allowable straight length should equal double the bend radius
centerRail = startSketchOn(YZ)
  |> startProfile(at = [-tubeDiameter / 2, grateThickness])
  |> yLine(length = tubeBend * 2)
  |> tangentialArc(angle = 30deg, radius = tubeBend, tag = $seg03)
  |> angledLine(angle = tangentToEnd(seg03), length = tubeBend * 2)
  |> tangentialArc(angle = -30deg, radius = tubeBend, tag = $seg04)
  |> angledLine(angle = tangentToEnd(seg04), endAbsoluteY = height - (tubeBend * 3.835), tag = $seg27)
  |> tangentialArc(angle = 45deg, radius = tubeBend, tag = $seg05)
  |> angledLine(angle = tangentToEnd(seg05), length = tubeBend * 2)
  |> tangentialArc(angle = -135deg, radius = tubeBend, tag = $seg06)
  |> angledLine(angle = tangentToEnd(seg06), endAbsoluteX = -tubeDiameter / 2)

// Sweep the tube profile around the center rail path to give it a thickness
centerRailThicken = startSketchOn(XY)
  |> circle(center = [0, -tubeDiameter / 2], diameter = tubeDiameter)
  |> sweep(path = centerRail)

// Model supporting ribs for the trolley frame
rib = startSketchOn(offsetPlane(XY, offset = 14))
  |> startProfile(at = [
       -(frameWidth - tubeDiameter) / 2 - .05,
       -.6
     ])
  |> arc(interiorAbsolute = [0, -3.15], endAbsolute = [-profileStartX(), profileStartY()], tag = $seg14)
  |> angledLine(angle = tangentToEnd(seg14) + 90, length = grateThickness)
  |> arc(interiorAbsolute = [0, -3.15 + grateThickness], endAbsolute = [-lastSegX(), lastSegY()])
  |> line(endAbsolute = [profileStartX(), profileStartY()])
  |> close()
  |> extrude(length = 1)
  |> patternLinear3d(instances = 3, distance = segLen(seg27) / 3, axis = [0, 0, 1])

// Create welded brackets to support the axle
brackets = startSketchOn(offsetPlane(YZ, offset = frameWidth / 2))
  |> startProfile(at = [-tubeDiameter, wheelDiameter / 2 - 3])
  |> yLine(length = 0.54, tag = $seg16)
  |> tangentialArc(angle = 60deg, radius = bendRadius, tag = $seg07)
  |> angledLine(angle = tangentToEnd(seg07), length = 2.58, tag = $seg15)
  |> tangentialArc(angle = -90deg, radius = bendRadius + grateThickness)
  |> tangentialArc(angle = 60deg, radius = 1.5)
  |> tangentialArc(angle = -90deg, radius = bendRadius + grateThickness, tag = $seg08)
  |> angledLine(angle = tangentToEnd(seg08), length = segLen(seg15))
  |> tangentialArc(angle = 60deg, radius = bendRadius, tag = $seg09)
  |> yLine(length = segLen(seg16))
  |> xLine(length = grateThickness)
  |> yLine(length = -segLen(seg16))
  |> tangentialArc(angle = -60deg, radius = bendRadius + grateThickness, tag = $seg17)
  |> angledLine(angle = tangentToEnd(seg17), length = segLen(seg15))
  |> tangentialArc(angle = 90deg, radius = bendRadius)
  |> tangentialArc(angle = -60deg, radius = 1.5 + grateThickness)
  |> tangentialArc(angle = 90deg, radius = bendRadius, tag = $seg18)
  |> angledLine(angle = tangentToEnd(seg18), length = segLen(seg15))
  |> tangentialArc(angle = -60deg, radius = bendRadius + grateThickness, tag = $seg19)
  |> yLine(length = -segLen(seg16))
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
  |> extrude(length = 0.75 * tubeDiameter, symmetric = true)

// Model a bearing for the axle on each bracket
axlebearing = startSketchOn(offsetPlane(YZ, offset = frameWidth / 2))
  |> circle(center = [-3.67, wheelDiameter / 2], diameter = 1)
  |> subtract2d(tool = circle(center = [-3.67, wheelDiameter / 2], diameter = .75))
  |> extrude(length = tubeDiameter, symmetric = true)

a = patternLinear3d(
  [brackets, axlebearing],
  instances = 2,
  distance = frameWidth,
  axis = [-1, 0, 0],
)

[
       grate,
       brackets,
       axlebearing,
       outerRailThicken,
       centerRailThicken,
       rib,
       a
     ]
  |> appearance(color, metalness = 40, roughness)


// Hand Trolley Wheel

// Set units
@settings(defaultLengthUnit = in)

// Import parameters
import * from "parameters.kcl"

// Revolve a wheel that mounts to the trolley axle
wheel = startSketchOn(offsetPlane(XY, offset = wheelDiameter / 2))
  |> startProfile(at = [
       -frameWidth / 2 - 0.65,
       -3.67 + 0.75 / 2
     ])
  |> xLine(length = -2.7)
  |> yLine(endAbsolute = -3.67)
  |> xLine(length = -0.5)
  |> yLine(length = 0.44)
  |> tangentialArc(angle = -85deg, radius = 0.2, tag = $seg21)
  |> angledLine(angle = tangentToEnd(seg21), length = 1.14)
  |> tangentialArc(angle = 85deg, radius = 0.1, tag = $seg22)
  |> angledLine(angle = tangentToEnd(seg22), length = 1.28)
  |> tangentialArc(angle = 85deg, radius = 0.1, tag = $seg23)
  |> angledLine(angle = tangentToEnd(seg23), length = 0.95)
  |> tangentialArc(angle = -80deg, radius = 0.2, tag = $seg24)
  |> angledLine(angle = tangentToEnd(seg24), length = 0.77)
  |> xLine(length = 0.15)
  |> angledLine(angle = tangentToEnd(seg24), length = -0.7)
  |> xLine(length = 2)
  |> angledLine(angle = -tangentToEnd(seg24), length = -0.7)
  |> xLine(length = 0.12)
  |> angledLine(angle = -tangentToEnd(seg24), length = 0.77)
  |> tangentialArc(angle = -80deg, radius = 0.2, tag = $seg25)
  |> angledLine(angle = tangentToEnd(seg25), length = 0.43)
  |> tangentialArc(angle = 85deg, radius = 0.1)
  |> yLine(length = -0.91)
  |> tangentialArc(angle = 85deg, radius = 0.1)
  |> angledLine(angle = -tangentToEnd(seg25), endAbsoluteX = profileStartX())
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
  |> revolve(axis = {
       direction = [1.0, 0.0],
       origin = [0.0, -3.67]
     })
  |> appearance(color, metalness, roughness)

tire = startSketchOn(offsetPlane(XY, offset = wheelDiameter / 2))
  |> startProfile(at = [-frameWidth / 2 - 3.55, -1.05])
  |> angledLine(angle = 100, length = 0.73, tag = $seg26)
  |> tangentialArc(endAbsolute = [lastSegX(), wheelDiameter / 2.1 - 3.67])
  |> tangentialArc(angle = 10deg, radius = 1)
  |> tangentialArc(angle = -90deg, radius = wheelDiameter / 100, tag = $seg12)
  |> angledLine(angle = tangentToEnd(seg12), length = 2.25)
  |> tangentialArc(angle = -90deg, radius = wheelDiameter / 100)
  |> tangentialArc(angle = 10deg, radius = 1)
  |> tangentialArc(endAbsolute = [lastSegX(), segEndY(seg26)], tag = $seg13)
  |> angledLine(angle = -100deg, length = segLen(seg26))
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
  |> revolve(axis = {
       direction = [1.0, 0.0],
       origin = [0.0, -3.67]
     })
  |> appearance(color = "#010101", metalness = 10, roughness = 70)

[wheel, tire]


hand-trolley

KCL