Utility Box

The Utility Box is a lightweight 250-liter cargo box designed for professional cargo bikes. Made from weather-resistant honeycomb polypropylene using 100% recycled plastic, the construction combines low weight with high durability.

Starting from an existing design concept, Helldorfer Engineering developed the box into a production-ready product. This included the hinge and locking mechanisms, optimization for series production, development of the polypropylene welding process, sourcing, assembly setup and quality control.

Series production started in February 2023. The box was initially developed for the Riese & Müller Load 75 and Transporter 85, while its modular construction allows adaptation to other cargo bikes.

Scope of work:

• Analyzing existing design

• Develop hinge and locking mechanism

• Redesign for series production

• Develop welding process of honeycomb Polypropylene

• FEM Simulation for critical parts

• Create Production and Assembly Drawings

• Source Parts and Materials internationally

• Setup Assembly Line

• Implement quality control