Shenzhen, China – September 2026
At ElisaCustom, we are known for our expertise in custom pixel lighting. But every now and then, a project comes along that pushes us beyond our comfort zone – and those are often the ones we learn the most from.
This is the story of Simon's custom DMX-controlled winch project – a challenging endeavor that tested our capabilities, required us to partner with the right experts, and ultimately delivered a product that exceeded expectations.
The Challenge: A Highly Specialized Request
Simon approached us with a very specific requirement: a DMX-controlled winch that would allow precise, programmable lifting and lowering of lighting elements for his stage and event productions. The specifications were clear:
Requirement | Specification |
|---|---|
Housing | Black shell |
Configuration | Single line drop |
Data cable | Cat5 in and through to the hook, or 4-core wire |
Lifting capacity | 2kg minimum |
Drop length | 5 to 10 meters |
Power input | TrueOne connector (Neutrik powerCON TRUE1) |
Data | XLR 5‑pin |
Through cable | EtherCon connectors on both base & hook ends |
While this was a well-defined specification, there was a significant challenge: we had limited experience with winch systems. Our expertise has always been in pixel lighting – LED strips, pixel modules, and controllers – not in mechanical lifting equipment that requires precision engineering and safety-critical design.
The Solution: Partnering with the Right Manufacturer
We knew that taking on this project alone would be a risk. So instead, we reached out to a specialized manufacturer with proven expertise in lifting and stage automation equipment. Their professionalism and commitment to quality gave us the confidence to move forward.
The collaboration process:
Step | Action |
|---|---|
1. Concept review | We shared Simon's specifications with the manufacturer and reviewed the initial design approach |
2. Iterative design | Multiple rounds of drawings were exchanged and refined |
3. Technical validation | The manufacturer's engineering team validated the design for safety and reliability |
4. Pre-production samples | Samples were produced and tested |
Key advantage: The manufacturer's experience with lifting mechanisms and DMX integration complemented our knowledge of lighting control and pixel systems perfectly.
The Journey: Multiple Rounds of Revision
One of the most critical phases of this project was the pre-production design stage. Before any sample was manufactured, we went through several rounds of drawing modifications with the manufacturer.
What was revised:
Mechanical structure: Ensuring the black shell housing was both durable and visually consistent
Cable management: Validating the Cat5 and 4-core wire routing for reliable data transmission
Connector integration: Confirming TrueOne power input, XLR 5‑pin data, and EtherCon through-cable connections would work seamlessly
Lifting mechanics: Verifying the 2kg minimum lifting capacity and 5‑10m drop length
Each iteration brought us closer to the final design, and the manufacturer's responsiveness and attention to detail were instrumental in getting it right.
The Outcome: A Satisfied Client
When the production samples were ready, we sent them to Simon for approval. His feedback was positive – the product met his expectations and performed as intended.
After receiving the final shipment, Simon reported that the winches were working smoothly and reliably in his production environment. This was the ultimate validation – not just of the product itself, but of the partnership and process that made it possible.
Key Lessons Learned
Lesson | Why It Matters |
|---|---|
Know your limits | Recognizing gaps in our expertise allowed us to seek the right partner |
Partner with experts | The manufacturer's specialized knowledge was essential to the project's success |
Iterate early | Multiple design revisions before production saved time and cost in the long run |
Test thoroughly | Pre-shipment samples and client confirmation ensured the final product met expectations |
Communication is key | Clear, continuous dialogue between all parties – us, the manufacturer, and Simon – kept the project on track |
Applications for DMX-Controlled Winches
Application | Why It Fits |
|---|---|
Stage productions | Precise, programmable lifting of lighting elements and props |
Concerts and events | Dynamic movement of screens, drapes, and scenic elements |
Theater and performing arts | Automated set changes and flying effects |
Exhibitions and trade shows | Flexible reconfiguration of displays |
Summary
Advantage | Benefit |
|---|---|
DMX control | Seamless integration with lighting consoles |
5‑10m drop length | Suitable for a wide range of stage heights |
Black shell housing | Professional, discreet appearance |
TrueOne power input | Reliable, hot‑plug capable connections |
EtherCon data through | Rugged, lockable RJ45 connectors |
2kg lifting capacity | Adequate for lightweight lighting elements |
Looking for Custom Stage Automation?
This project demonstrates our ability to tackle complex, cross‑disciplinary challenges – even when they fall outside our core expertise. By partnering with the right specialists, we can deliver solutions that meet your specific requirements.
👉 Contact Us Today to discuss your custom lighting or stage automation project.