From flight cases to mobile stages and set pieces, stage equipment is the backbone of any successful performance. Whether it’s orchestrating a quick change of stage layout or smoothly moving equipment on and off the stage, at WheelsWay, we provide durable caster wheels that can ensure the mobility of your equipment. Let’s rock and “Roll” !
Stage equipment castors are specialized casters or wheel assemblies designed to provide mobility and ease of movement for various stage-related equipment. These components play a crucial role in the entertainment industry, allowing for the seamless transport and positioning of stage equipment such as flight cases, mobile stages, backstage equipment carts, light stands, sound systems, scenery, and other essential elements of a performance.
Stage equipment casters are engineered to facilitate easy and smooth movement across different surfaces, including stage floors, ramps, and various terrains. This mobility is essential for efficiently positioning equipment during setup, rehearsals, and performances.
Given the dynamic and often hectic nature of stage environments, casters must provide stability to prevent accidental movements or shifts. Some caster models feature locking mechanisms to secure equipment in place once it has been positioned
Stage equipment is subject to frequent movement and heavy use, making durability a critical factor. High-quality materials and construction ensure that the casters can withstand the demands of the entertainment industry, providing long-lasting reliability.
Casters for stage equipment often incorporate swivel mechanisms that allow for easy maneuverability and precise positioning. This is particularly important when navigating tight spaces or making subtle adjustments to the placement of equipment.
To safeguard the surfaces of stages, studios, and performance venues, many stage equipment casters feature non-marking wheels. This prevents scuffs, scratches, and damage to sensitive flooring materials.
Certain casters incorporate shock absorption mechanisms to minimize vibrations, enhancing the overall stability of stage equipment.
Designing and manufacturing custom casters for an OEM project involves several stages, we follow a detailed step-by-step process to ensure that your project runs smoothly and without any problems
Define requirements: Understand the customer’s specific needs and requirements. Consider special attachments, test standards, and industry standards. Give suggestions to improve the caster performance if the customer wants to eliminate the failure issues from their existing casters.
Material selection: Select appropriate wheel materials for the casters based on factors like load capacity, environmental conditions, and durability requirements.
Technical Drawings: Make detailed 2D/3D technical drawings of the caster based on the customer’s requirements or samples.
Prototyping: Develop prototypes to test the functionality and performance of the casters. It can be a 3D printing model or a small batch for initial testing.
Tooling and Equipment Setup: On the basis of the finalized design, set up and adjust the necessary tooling and equipment for mass production.
Production of Components: Manufacture individual caster components such as wheels and frames, according to technical specifications in confirmed drawings.
Surface Treatment: Apply surface treatments to enhance the aesthetics, corrosion resistance, hardness, or other functional aspects of the casters.
Assembly: Assemble the casters, making sure that each unit meets the design specifications and quality standards.
Load Testing: Test the casters according to the dynamic load test standard, such as EN12532, or conform to the test requirements of the customer. To ensure that the casters can handle the specified weight capacities without failure.
Durability Testing: Test the casters for durability under various conditions, such as different floor surfaces and temperature extremes, according to the customer’s demand.
Quality Control Checks: Implement ISO9001 quality control measures throughout the manufacturing process. Identify and correct any defects.
Packaging: Develop packaging solutions that protect the casters during transportation and storage.
Shipping Logistics: Plan and coordinate the logistics for shipping the casters to the client, and confirm the paperwork details with the customer, such as invoice and packing list, bill of lading, Certificate of Original, Form E, etc.
Customer Support: Provide ongoing support to address any queries, concerns, or further needs that the client may have after receiving the casters.
Cutting metal sheets into pieces, punching out the specific shape of top plate, fork, brake pedal, etc.
Bending the shaped pieces and form it into the caster fork, forming the steel ball track on the top plate sheet, etc.
Zinc plating, chrome plating, electrophoresis, etc.
Nylon wheel, PU wheel, TPR wheel, plastic wheels injection and die casting cast iron wheels.
Assemble all the caster components into one complete piece
Pack the casters in export grade thick carton box. Plastic bag, lable sticker, inner box, wooden crate, wooden pallet packing are also available.
Here’s the formula for calculating load capacity per caster:
Load per caster with safety factor = (total load × safety factor) / number of casters
“Total Load” is the equipment’s net weight plus its maximum additional load
“Safety Factor“ is an additional weight allowance added to the calculated load per caster to ensure that the casters can handle unexpected or temporary overloads, variations in load distribution, and wear & tear over time. It typically ranges from 1.0 to 3.0, although the specific value can vary depending on the application and industry standards.
The bigger the wheel, the easier to push the caster forward, because it can roll over obstacles or rough and uneven surfaces more easily. This is because when the wheel is larger, obstacles look smaller compared to the wheel’s size, making it roll over them more smoothly.
However, larger wheels will elevate the center of gravity, when you want to make sure things don’t tip over, especially if what you are carrying is heavy on top, smaller wheels are the better options. What’s more, smaller wheels can increase the force required to move, which will help the equipment to stay in place.
Another factor to consider is safety. It’s recommended that the total height of what you’re moving, including wheels and loaded goods, does not exceed 1400 mm. This will help to see better and avoid accidents.
The following table describes the characteristics of some typical working environments that stage equipment casters often encounter.
| Application Environment | Environment Condition | Wheel Material Preferred | Noise Level Required | Cleaning | Corrosion Resistance necessity |
| Theater Stages | Smooth, flat surfaces with occasional debris or cables | Polyurethane or rubber for smooth rolling and floor protection | Low-noise, to minimize disruption during performances | Casters should be easy to clean to remove dust and debris | Moderate resistance to corrosion due to occasional exposure to stage fluids (like fake blood or water) |
| TV and Film Production Sets | Variable surfaces including smooth studio floors, carpets, and outdoor terrain | Polyurethane or rubber for versatility and shock absorption | Low to avoid picking up unwanted sounds during filming | Casters should be easy to clean to remove dust, dirt, and studio equipment residues | Moderate resistance to corrosion due to exposure to various studio chemicals and cleaning agents |
| Concert Stages | Often uneven or sloped surfaces with heavy equipment loads | Polyurethane, rubber | Moderate, as some noise may be acceptable in a concert setting | Casters should be resistant to mud, water, and debris common in outdoor concert venues | High resistance to corrosion due to exposure to outdoor elements and frequent use in wet conditions. |
| Sports Arenas | Variable surfaces including smooth indoor floors and outdoor fields | Depending on the surface, polyurethane or rubber for indoor floors and pneumatic or solid rubber for outdoor fields | Low-noise | Casters should be resistant to mud, water, and debris common in outdoor sports fields | Moderate |
Choosing the right material depends on several criteria, the table below shows the types and their main characteristics.
| Polyurethane | High | Good | Good | Low |
| Elastic Rubber | Medium to high | Good | Good | Low |
| Nylon | High | Fair | Excellent | Moderate |
| Plastic | Medium to high | Fair | Fair | Low |
| Pneumatic rubber | Medium | Excellent | Good | Good |
| Thermoplastic Rubber | Medium | Good | Good | Low |
Plain bearing
The plain bearing is a simple and cost-effective wheel bearing, which is durable and free of maintenance under normal conditions. Plain bearings are mainly used for light-duty and low-speed applications. Since overheating can occur at high speeds under heavy loads, plain-bore cast iron wheels require regular lubrication.
Roller Bearing
The roller bearing is a sturdy, long-life grease lubricated, and maintenance-free wheel bearing type that consists of steel rollers(needles) fitted into a plastic or steel cage. These rollers roll between the axle tube and the wheel hub. As the wheel rotates around the axle, it has only rolling friction rather than sliding friction, resulting in low rolling resistance, even under heavy loads. In addition to the standard version, roller bearings are also available in stainless steel.
Ball Bearing
A central ball bearing ensures precise, smooth running and effective sealing. it is integrated or injected directly into the wheel center. Two sealing caps are fitted as standard for added protection. Lubricated with long-life grease, these bearings are maintenance-free under regular conditions.
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Most frequent layout for heavy loads and long distances | Affordable, easy to keep on a straight line, easy to nevigate |
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Used on ramps are not recommended | Easy to handle |
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For applications requiring lateral movement | Easy to push and pull, make sharp turns and navigate corners smoothly |
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Light loads, used on ramps are not recommended | Economic positioning |
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For heavy loads, precise steering | Easily turned and rotated, easily positioned in tight spaces, and change directions quickly |
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For very heavy loads and long travel times | The 2 fixed casters allow the weight of the load to be distributed over the 4 swivel ones |
While some casters may be suitable for multiple types of stage equipment, it’s essential to consider the specific requirements of each piece of equipment and choose casters accordingly.
The best type of casters for stage equipment is typically those with swivel or rigid configurations, depending on the maneuverability needed for the equipment. Additionally, casters with non-marking wheels are preferred to protect the stage surface.
Various factors including dirt, pet fur, lint from high-pile carpets, dust, threads, fabric remnants, hairiness, and poor-quality lubricant can cause poor rotation of caster wheels. In addition, small items like beads, pebbles, screws, or glitter can get stuck in the caster and prevent them from turning smoothly.
Typically, four caster wheels are necessary to make the equipment mobile. To ensure compliance with weight specifications, follow a straightforward calculation process. Firstly, calculate the total weight of the load. Next, divide this figure by your proposed number of casters. If the outcome is below the load capacity limit for each caster, you are on the right track in picking the suitable caster.
Your choice of caster size should depend on how you intend to use them. A bigger caster is better for heavy materials. For example, if you’re designing a workbench, you’ll need to support more weight, so larger casters are more suitable, however, smaller casters are a better option when what you are carrying is heavy on top and you want to make sure things don’t tip over. Smaller casters are suitable for carpets and soft surface.
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