The Power of Prototyping: Creating an Ergonomic Lifter from Scratch

As much as I enjoy building completely custom pieces, I’ve always found prototype work to be some of the most exciting and rewarding projects we take on. Every so often, we get the chance to create something entirely new… something so specialized that no off-the-shelf solution even comes close. This isn’t just about making a one-off or a custom variation of an existing product. This is about developing something from the ground up, designed with the intention of being replicated and put into real-world use.

Recently, we were commissioned to design an ergonomic lifter for a client who processes hundreds of crates every single month. Picture a sea of crates taller than a person, filling 7,500 square feet of floor space… and that’s just their shipping area. Each crate has three main components: a standard pallet base, an access panel on the front, and a final assembly that forms the remaining four sides. The strain of repeatedly lifting that heavy outer assembly was the exact problem this prototype aimed to solve. And the challenge? Nothing available on the market even came close to meeting the client’s needs.

The client came to us with an initial concept but was open to improvements. At JF Fabrication, we recommended an all-welded design for greater durability and longevity—something that would hold up under constant daily use. On top of that, their compliance and safety teams required a locking mechanism that could automatically lock in one of five positions… all without forcing workers to take their hands off the controls. Every detail needed to meet strict safety standards before approval.

One of the biggest wins in the final design was ergonomics. Instead of lifting panels upward—a movement that puts stress on the back and shoulders, the operator now simply pushes down to remove the crate sides. It’s a small change with a big impact, reducing fatigue and streamlining the process for employees handling hundreds of crates day after day.

Safety was equally critical. With our design, operators keep their hands completely clear of pinch points, and the machine automatically locks in five different positions. This extra layer of security not only met the company’s compliance requirements but gave employees more confidence while using the equipment.

Of course, getting to this point took time. Like any prototype, this project went through multiple iterations. We refined the locking mechanism several times to get the strength and usability just right, and we adjusted the lifting bar to balance smooth operation with long-term durability. That’s the beauty of prototyping—every revision gets you closer to the perfect solution.

The client is now in the evaluation phase, testing the lifter in daily operations. Early feedback has been overwhelmingly positive, and they plan to build additional units for internal use once testing is complete.

This project is a great example of why custom fabrication and metal prototyping matter. Off-the-shelf equipment couldn’t solve this client’s challenge: but our team at JF Fabrication could. With our experience in metal fabrication in Atlanta, we were able to take their concept, refine it, and deliver a purpose-built solution that works exactly the way they need it to.

Whether it’s a specialized tool, ergonomic equipment, or a one-of-a-kind prototype, we thrive on tackling the problems that mass-produced equipment simply can’t solve.