Airline catering trolleys play a crucial role in in-flight service and logistics, yet current trolleys are shipped fully assembled, resulting in the inefficient transport of large volumes of air. This leads to high shipping costs and a significant environmental footprint, conflicting with the aviation industry’s increasing focus on sustainability and cost optimisation. This project aims to develop an innovative airline catering trolley that can be transported as a flat-pack solution, enabling more trolleys to be shipped in the same volume while maintaining strength, safety, and usability during assembly and operation. Following an iterative design process, including market research, concept development, technical feasibility studies, and prototyping, structural simulations and cost analyses were performed to validate mechanical integrity, assembly ease, and economic benefits. The final design is a re-engineered flat-pack trolley based on the original Driessen trolleys, which can be folded into a compact, flat package with the use of hinging snap-fit corer pieces. This simplistic design ensures that the trolley remains lightweight. This design reduces transport volume by 42.5%, resulting in equivalent emission reductions and cost savings during distribution. The flat-pack trolley meets strict certification standards, can be assembled without tools in under five minutes, remains airtight and lightweight, and fits standard galley dimensions. Its fool-proof design ensures safe and intuitive handling. However, the reliance on snap-fit connections introduces challenges, including strict tolerance requirements and potential metal fatigue, which may affect long-term durability and the ability to achieve a 10-year service life. This project directly addresses the demand for innovative, sustainable solutions in aviation by offering economic advantages through lower transport costs, while also strengthening airlines’ environmental and brand positioning.