Ind. Tote | Mysite

FORGE

Forge is a family of heavy duty industrial totes with snap-on lids designed to meet Sterilite's market expectations while addressing the needs of consumers seeking durable and versatile storage solutions. Developed to compete directly with existing products in the market, the collection focuses on functionality, strength, and ease of use.

Launch Year; 2024

Project Duration; 10 months

My Role: Led the design project from competitive research and concept development through production CAD, prototyping and final product development. Collaborated with engineering, marketing and retail teams to resolve structural, manufacturing and brand requirements.

Background

The main focus of the project aimed to develop a family of heavy-duty storage totes inspired by the HDX product line while delivering the functionality, durability, and competitive advantages required to succeed in the industrial storage market.

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HDX Heavy Duty Tote

Sterilite Heavy Duty Tote

Design Requirements:

Incorporate a deep-index lid (7/8"–1") with a tight lid-to-base connection for secure stacking.
Integrate strap channels and through-holes for bungee cords, locks, and zip ties with a drip-resistant design.
Support 75 lbs of internal load capacity.
Withstand up to 900 lbs of distributed stacking load for the 27-gallon version.
Design handles capable of resisting up to 680 lbs of force.
Maintain specified wall thicknesses while ensuring manufacturability and structural performance.
Accommodate multiple sizes, including 27-38–40-gallon variants.

Analysis of Existing Industrial Totes

Competitive heavy-duty storage products from various brands were evaluated based on their form language, functional features, structural solutions, modularity, and manufacturing details to establish design benchmarks and guide the development process.

Mapping Key Points

The mapping research defined the key principles that shaped the design direction. The product was developed to be rugged, tough, and aesthetically pleasing while remaining competitive in the market. Functional requirements such as easy stacking, nesting, modularity, secure lid snapping, and efficient merchandising were also identified as essential design drivers.

Moodboard

Idea Exploration

Production Ready CAD Details

Forge is a family of heavy-duty totes with snap-on lids designed to meet Sterilite's market goals and consumers' demand for durable, versatile storage solutions. Developed to compete in the industrial storage market, the collection emphasizes strength, functionality, and ease of use, while incorporating two distinct lid designs; one tailored to Target's design language and another aligned with Sterilite's brand identity.