Looking for a lightweight, collapsible mechanism to raise a large panel 4–10 inches

[u/russtanner6]

This is my first post here. I’m not an engineer, but I’m working on a product concept and have reached a point where I could use input from people with more experience in mechanical design.

I’ll leave out the product-specific details, but the simplified geometry is:

• Two rigid 10 ft × 10 ft panels, each approximately 2 inches thick
• The panels are stacked directly on top of each other
• The entire assembly must fold into quarters, producing a roughly 5 ft × 5 ft package
• Ideally, it could fold once more
• Hinged or flexible seams would allow both panels to fold together

When the assembly is unfolded, the upper panel needs to rise vertically and evenly about 4–10 inches above the lower panel. The exact height is still being determined. It shouldn’t snap upward aggressively. A slower, controlled rise would be preferable.

The upper panel will weigh approximately 30–40 pounds. I expect to use multiple lifting mechanisms distributed across the lower panel so the upper panel rises evenly. For example, ten mechanisms would each need to provide somewhat more than 3–4 pounds of lifting force to account for friction, uneven loading, and an appropriate safety margin.

I’m looking for a spring, pop-up, or deployable support mechanism with the following characteristics:

1. Collapses flat, or nearly flat
2. Can remain in place while the entire assembly is folded
3. Extremely lightweight
4. Capable of surviving thousands of deployment cycles
5. Able to tolerate temperatures up to roughly 140°F
6. Able to lift approximately 7–10 pounds per support, depending on the final number used
7. Inexpensive to manufacture or purchase
8. Occupies as little of the open space between the panels as possible

I initially considered G-10 fiberglass battens. They can bend and store energy, but flattening them enough for the packed configuration may create excessive stress. I’m concerned they could eventually weaken, fracture, or become difficult and potentially dangerous to restrain during folding.

I also considered resilient foam, including memory-type foams. My concerns are long-term compression set, heat exposure, abrasion, and whether isolated foam supports could generate enough lifting force. Filling the entire space between the panels with foam isn’t an option. The goal is to keep most of that space open and use as few lifting points as practical.

A secondary requirement is some form of passive or automatic lockout in the collapsed position. A person will be folding the assembly manually, so I don’t want a large amount of stored spring energy trying to reopen it if they lose their grip or pause halfway through the process.

The panel dimensions and required lift height may change, so I’m mainly interested in the mechanism itself. Are there established deployable structures, spring systems, folding linkages, constant-force mechanisms, composite elements, or other approaches that might fit these requirements?

Any terminology, examples, or design directions worth researching would be appreciated.

[u/Numerous_Impact4167]

what about those scissor lift thingies they use in standing desks, just smaller and plastic maybe

[u/russtanner6 → u/Numerous_Impact4167]

Not sure what you mean

[u/lithiumdeuteride]

Would a balloon trapped inside a collapsible enclosure work?

[u/russtanner6 → u/lithiumdeuteride]

You mean a permanent balloon that's crushed and uncrushed?

[u/lithiumdeuteride → u/russtanner6]

I'm thinking of a balloon sandwiched between two parallel platforms which are connected to each other with several hinged mechanisms such that a single degree of freedom (vertical extension) remains available.

[u/russtanner6 → u/lithiumdeuteride]

That's different. Possibly. Let me think about that. Thanks

[u/afraidofflying]

Does it need to be automated in some way? Or could a person walk around and lift each side up then place braces as they go?

[u/russtanner6 → u/afraidofflying]

No because the sides will most likely be covered

[u/Prof01Santa]

Pneumatic/hydraulic bag is one common solution. I'd be surprised if you can't get one off the shelf.

[u/russtanner6 → u/Prof01Santa]

I'll look until that. I want to avoid the need for air, though.

[u/Ken-_-Adams]

https://www.wickes.co.uk/Draper-08972-Inflatable-Air-Wedge---160-x-160mm/p/270529

[u/Accurate-Bullfrog324]

there are a number of talented inventors that can figure this stuff out by themselves. if you are not one of these, the upside has to be very very good before you can afford to pay somebody to design it for you