The Challenge
Installing lifts within existing shopping centres presented a significant engineering constraint for our client. Many sites already had finished floors, making the excavation of a conventional lift pit disruptive, costly or impractical.
The lift itself was suitable for these environments, but the depth required by the existing base design was preventing installations from going ahead and limiting potential sales.
Identifying the Opportunity
Rather than treating the installation constraint as unavoidable, Design 4 Solutions looked at whether the lift base itself could be redesigned.
The objective was to develop a lower-profile solution that reduced the required threshold depth while retaining compatibility with the client’s existing lift components and installation process.
This would allow the client to target sites that had previously been unsuitable without requiring installation teams to adopt an entirely different lift system.
Developing the Low-Profile Lift Base
Working with a local manufacturer, we developed a new lift car base with a reduced threshold depth.
The engineering work included:
- Structural calculations
- 3D CAD modelling
- Detailed engineering drawings
- Development of testing protocols
- Consideration of compatibility with existing components and installation requirements
By designing around the client’s existing system, the new base could address the installation constraint without unnecessarily changing other established elements of the product.
Testing the Design
Testing protocols were developed to assess the strength and performance of the redesigned base before it was introduced into use.
This formed an important part of the development process, allowing the new design to be evaluated against the requirements of the application rather than progressing directly from CAD into installation.
The Results
The redesigned lift base enabled the client to pursue installations at sites that had previously been impractical because of the required pit depth.
The project resulted in:
- 200% increase in sales from previously inaccessible sites
- Access to new installation opportunities within the retail sector
- Compatibility with the client’s established installation approach
- A stronger product proposition for the client’s sales team
The project demonstrates how addressing a specific engineering constraint can do more than improve a product. In this case, redesigning one component opened up new commercial opportunities for the wider lift system.
Product Design for Real-World Engineering Constraints
Product development often involves improving an existing design rather than starting again from scratch.
By understanding the installation constraint, existing components and manufacturing requirements, Design 4 Solutions was able to develop a targeted engineering solution without unnecessarily redesigning the complete lift system.
Our product design, CAD and design for manufacture services support businesses facing similar challenges with existing products and components.
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