US Forklift Market Size & Share Analysis - Growth Trends & Forecasts (2025 - 2030)

US Forklift Market Trends and Insights

Expansion of e-commerce warehousing

Daily parcel volumes surpassed 16.5 million units in late 2024, pushing fulfillment operators to retrofit or build high-throughput sites.^{[3]Logistics Management, “E-Commerce: Logistics Redefined,” logisticsmgmt.com} DHL Supply Chain’s purchase of IDS Fulfillment added 1.3 million ft² of space across several states, underscoring sustained capacity growth. High-density designs favor narrow-aisle and pallet truck formats, intensifying demand for Class 1 and Class 3 units able to maneuver within 40-foot clear heights. Ninety percent of logistics firms plan significant digital-supply-chain investment, creating a premium sub-segment for sensor-rich trucks that integrate with warehouse-management systems.

Shift to electric forklifts due to emission regulations

California’s Zero-Emission Forklift Regulation bans new gasoline and propane deliveries starting 2026 and covers nearly 89,000 large-spark-ignition trucks.^{[4]California Air Resources Board, “Zero-Emission Forklifts,” arb.ca.gov}Electric models now account for 71% of North American sales, driven by maintenance savings of up to 50% and fuel savings near 80% compared with ICE units. Hyster’s lithium-ion series lifts 40,000 lb, matching combustion performance and dispelling capacity concerns.

Automation & warehouse digitalization (smart forklifts)

IoT-enabled forklifts equipped with lidar and AI position sensors are cutting handling times and addressing labor shortages. SEER Robotics introduced autonomous models in 2025 that navigate mixed environments and raise throughput by up to 40%. ^{[5]SEER Robotics, “Streamlined Warehousing Begins with Smarter Forklift Technology,” seer-group.com} ArcBest’s Vaux platform layers fleet-management software over AMR trucks, allowing remote, autonomous, and manual modes that conserve operator headcount.

Forklift-as-a-service subscription uptake

Jungheinrich’s Full Flex Rental offers 12-month cancelable contracts combining equipment, maintenance, and fleet analytics. The model shields users from capex, aligns fleet size with seasonal peaks, and ensures rapid access to new technology—advantages that resonate as economic volatility persists and service quality rises to parity with hardware performance.

Shortage of skilled forklift operators

Warehousing wages are rising 4-5%, yet retirements and pandemic exits leave certified-operator positions unfilled. The National Safety Council recorded 73 lift-truck-related fatalities in 2022, highlighting the safety cost of inexperience. Companies are funding accelerated training, flexible rosters, and operator-assist technologies to keep facilities productive.

High upfront cost of Li-ion & fuel-cell forklifts

Advanced trucks cost 2-3 times legacy models, and California regulators estimate a USD 2.7 billion compliance bill for local entities. Although lifecycle economics favor electrics over 5-7 years, SMEs struggle with initial outlays, slowing adoption outside strongly regulated regions.

Segment Analysis

By Class: Narrow-Aisle Specialists Dominate

Class 2 vehicles captured 33% of the US forklift market in 2024, reflecting the premium placed on cubic-space efficiency inside e-commerce fulfillment centers. Class 1 electrics show the fastest 2025-2030 growth at 9.5% due to their versatility and regulatory momentum. Safety-focused sensor suites highlighted during National Forklift Safety Day 2024 are now standard, elevating unit pricing yet lowering incident costs.

Automation penetration is highest in Class 1 and 2 lines as OEMs embed lidar, SLAM mapping, and fleet-orchestration software. AutoXing’s January 2025 launch underscores this shift with Smart Forklifts able to switch between autonomous and manual modes. The US forklift market increasingly segments into autonomous premium tiers and conventional economy tiers, reflecting divergent buyer ROI thresholds.

Note: Segment shares of all individual segments available upon report purchase

By Power Source: Electric Revolution Accelerates

Electric units held 60% of 2024 volume and, propelled by California’s rule, the US forklift market is on track for 11.2% electric CAGR through 2030. ICE trucks still dominate outdoor, heavy-duty roles with 39 % share, yet technological parity is narrowing as lithium-ion packs power 40,000-lb lifts.

Telematics native to electric platforms deliver real-time productivity and safety dashboards. Southern Glazer’s Wine & Spirits uses digital safety checks to guide maintenance cycles, demonstrating how data loops convert power-train shifts into operational gains. Over time, US forklift market economics will increasingly hinge on software-enabled efficiency rather than raw equipment capacity.

By Load Capacity: Lightweight Leaders

Sub-5-ton forklifts represented 45% of 2024 shipments, mirroring demand for agile units in retail and assembly-line settings. The 5-15-ton segment will outpace others at 8.3% CAGR, powered by medium-duty manufacturing and the autonomous-forklift boom. Above-15-ton machines remain staples in construction supplies and metals handling.

Electric innovations are cascading upward; Hyster’s high-capacity lithium-ion series erodes ICE advantages in ports and steel mills. Walmart’s deployment of autonomous medium-capacity forklifts illustrates mainstream acceptance of automation to offset labor gaps. This traction ensures that US forklift market size gains in mid-capacity bands will stay aligned with automation rollouts.

By Battery Type: Lithium-Ion Leads the Charge

Lithium-ion captured 54% share in 2024, a milestone driven by fast-charge, opportunity-charge, and maintenance-free benefits. With a 14.1% projected CAGR, lithium-ion will dominate US forklift market size growth over the decade. Lead-acid retains relevance in budget-sensitive fleets but faces intensifying TCO scrutiny.

Flux Power’s partnership with a top OEM to launch UL-certified S-Series packs signals vertical integration between battery startups and incumbents. Education campaigns are dismantling myths around lithium safety and heavy-lift suitability, thereby broadening the US forklift market acceptance curve.

By End-User: E-Commerce Drives Demand

Logistics controlled 28% revenue in 2024, underpinned by omnichannel distribution networks. Retail-e-commerce is the fastest-growing customer set at 12.4% CAGR to 2030, spurred by consumer same-day expectations and the surge in less-than-truckload parcel flows. Industrial plants still contribute 35% share, offering baseline stability.

Specialized niches, such as chemical handling with explosion-proof requirements, command premium pricing. As 90% of logistics providers budget for digital-supply-chain upgrades, end-users evaluate forklifts not just on lift metrics but on data compatibility and lifecycle emissions—criteria reshaping the US forklift market procurement playbook.

Geography Analysis

The South accounts for 38% of the US forklift market in 2024, reinforced by reshoring trends, competitive land costs, and deepwater port connectivity. The region’s 6.8% forecast CAGR also reflects state-level initiatives to align vocational training with logistics needs. HydroFleet’s USD 33 million facility in Pooler exemplifies new capital flowing toward Southern distribution hubs.

The Northeast maintains demand density in legacy industrial zones where narrow-aisle electrics help offset high real-estate costs. Yet older buildings often need electrical-service upgrades before fast-charge systems can be installed, lengthening payback horizons. Crown Equipment’s new Ohio site indicates corporate confidence in regional after-sales coverage.

The West, heavily influenced by California’s regulations, accelerates early adoption of zero-emission fleets and hydrogen pilots at maritime terminals. Clean-Ports funding creates a testing ground for hydrogen forklift economics, potentially exporting best practices nationwide. Collectively, these dynamics keep US forklift market growth widely distributed but governance-driven in coastal jurisdictions.