ACV Auctions approached us to assist in the production of their virtual lift, a device designed to scan the underside of cars quickly and efficiently. While the functionality of the design had been established, the challenge lay in creating a solution that was easy to use, manufacturable, and durable. Our team devised an aluminum extrusion-based design that addressed these concerns.

To ensure ease of use, we focused on minimizing secondary actions and incorporating off-the-shelf parts where practical. By doing so, we aimed to simplify the operation of the device and enhance user experience. We also took into account the limitations of certain parts, such as poor tolerances, during the design phase.

In terms of functionality, we aimed to maintain the spacing and operational features of the previous prototype. This included ensuring a seamless connection between the phone and the mirror, as well as setting the appropriate angle for the mirror and LED lights. Additionally, we ensured that the device could comfortably fit between the wheels and underneath the clearance of most cars. It was crucial for the device to be compact enough to fit in the trunk or backseat of most vehicles without causing inconvenience.

Durability was another important consideration. We wanted the device to withstand accidental drops while protecting its internal components. Therefore, we prioritized sturdiness and incorporated protective measures into the design.

To facilitate manufacturing, we utilized a combination of 3D printing (specifically SLA and SLS techniques), CNC machining, and the integration of off-the-shelf components. This approach allowed us to streamline the production process and minimize the need for large tooling required for injection molded parts.

Throughout the prototyping phase, we refined the design using a combination of these techniques. By iterating and testing various iterations, we aimed to achieve a final product that met all the specified requirements.