CASE STUDY 03 / MECHANICAL SYSTEMS
Affinity Airlift Stand.
Built around the lift. Engineered for the setup.
THE PROJECT, IN BRIEF
Built around the lift. Engineered for the setup.
A square-base lighting stand developed for Affinity Event Group, combining a stiffer structure with an internal lift-assist mechanism.
- CLIENT / CONTEXT
- Affinity Event Group
- PROJECT OUTPUTS
- Telescoping stand and lift-assist CAD · Structural FEA and connection checks · Fabricated and assembled prototype · Engineering files for client evaluation
- THE RESULT
- A fabricated lift-assist prototype and engineering package delivered for client evaluation, with assembly and comparison demonstrations.
01 / The challenge
Start with the demands of a real event setup.
Affinity Event Group needed a square-base lighting stand that felt more stable under mounted equipment and made the lift easier for event crews. The brief brought structure, handling, and presentation together in one product.
The stand needed to remain transportable and visually appropriate for events. Increasing rigidity and integrating assistance could not make everyday deployment unnecessarily complicated.
- Improve lateral stiffness in a square-base format
- Assist lifting of mounted lighting equipment
- Retain practical transport and deployment
02 / Mechanism development
Package the assistance inside the mast.
An internal gas spring became the center of the lift-assist concept. Its travel, mounting points, and relationship to the telescoping tubes were developed together so the mechanism could stay within the stand’s clean external form.
Printed bearing sleeves guided the moving tube. Prototype fit-up provided a way to refine those interfaces alongside the clamp and stop features.
- Gas-spring travel coordinated with the telescoping mast
- Printed sleeves to guide the moving tube
- Clamp and stop details refined during fit-up
03 / Structural engineering
Follow the load through the structure.
The structural work addressed the tubes, plates, and connections as a connected assembly. FEA was used to evaluate plate and tube behavior, supported by hand checks of the M20 base bolt and thread engagement.
The resulting prototype combined substantial tubing, waterjet-cut plates, and welded base hardware. Fabrication details were developed alongside the analysis so the proposed structure could be built and assembled.
- FEA of the plate and tube structure
- Hand checks of the M20 connection and thread engagement
- Waterjet plates and welded base hardware
04 / Prototype evaluation
Build it. Assemble it. Compare it.
Fabrication included welding, tapping, and full assembly. That work tested the design as a physical system, from the base connection to the mast and mounting hardware.
A wobble comparison made the difference against a market-reference stand observable. The prototype was also presented at an expo for feedback from DJs, bringing practical setup experience into the evaluation.
- Full prototype fabrication and assembly
- Comparative observation of lateral movement
- Lift-assist demonstration and feedback from event users
05 / The result
Give the client something concrete to move forward with.
The project concluded with a working prototype and engineering files for Affinity Event Group to evaluate and advance. The handoff connected the design intent with hardware the client could assemble, operate, and review.
The work brought mechanism design, structural evaluation, and fabrication into one complete handoff. It gave the client a concrete basis for the next product decisions.
- Prototype delivered for client evaluation
- Engineering files prepared for continued development
- Lift assistance integrated into a square-base stand
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