In early 2021 we began working with the team at Denver based Zipline Gear on their innovative trolley concept. Our design team integrated into the development process as the team at Zipline came to us with a proof of concept prototype. Designing a final product that was visually and mechanically sound while being manufacturable in house at Zipline Gear was our goal.

 The Zipline team built final prototypes and just released the Boomerang Trolly to consumers this Spring.

The Boomerang is a remote controlled, trolley return system designed for zip lines built over terrain that makes it inconvenient to return the trolley to the origin point. If you’re planning to build a zip line that runs over water, rough terrain, or sits too high for a regular trolley walk-back, then the Boomerang is for you.

The design features aluminum housings machined in house as well as grips comfortable for all hands in all conditions. The parallel grips allows for greater stability and comfort during the ride. The return mechanism disengages while weight-bearing for safety and comes with a single replacement kit for wearable parts.

Specs:

Weight: 6.5LBS

Handlebar Weight Capacity: 350LBS

Return speed: 25 mph

Battery life: Approximately 60 Returns based on a 150’ zip line

The prototype that the Zipline Gear Team developed proved that the concept was a viable product. We were brought on to the project to provide mechanical engineering support, human factors considerations, and improve overall aesthetics. Our team integrated into the development process as the team at Zipline to reach a final design ready for market.

The Zipline Gear Team sent NaterTater a pre-production version of the Boomerang to test out on his over the pond zip line. Check out the video below to see it in action.