How to Build a Flip-Down TV Lift: Full Guide with Force and Lever Mechanics
Looking to hide your TV in the ceiling and have it flip down at the push of a button? A flip-down TV lift system powered by a linear actuator is the perfect solution—sleek, space-saving, and just plain cool. But to build one properly, you’ll need more than a bracket and an actuator. The real secret is understanding the mechanical forces at play, especially lever principles and how they impact actuator load.
In this post, we'll walk through how to build your own flip-down TV lift step-by-step, while also explaining why force calculations are critical to your success—especially if you're working with a large TV.
🧠 How It Works (Quick Summary)
This system is based on a simple but powerful mechanical idea: a rotating bracket mounted to a pivot point, with a linear actuator attached to push and pull the bracket into its open or closed position.
At a glance, the mechanism includes:
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A pivot point: Acts as the axis of rotation.
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A TV bracket: Mounts to the TV and rotates with the pivot.
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A linear actuator: Extends and retracts to rotate the bracket.
When the actuator extends, the bracket rotates downward, lowering the TV into a vertical viewing position. When it retracts, it pulls the bracket back flush with the ceiling.
Sounds simple, right? But here’s where it gets interesting—and where most people underestimate what’s involved.
⚙️ Lever Mechanics: Why Force Matters
Your TV bracket acts as a lever—more specifically, a First-class lever. And when you add a heavy object like a 60" flat screen to the end of that lever, the force required to move it increases rapidly depending on:
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The weight of the TV
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The length of the bracket below the pivot
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The position where the actuator connects on the other side of the pivot
📏 Let’s Use a Real Example
Imagine you're mounting a 60" TV. Typically, a TV that size is around 30" tall and weighs about 50–60 lbs.
You’d build a bracket that drops down at least 35" from the pivot to securely support the TV.
Now here’s the important part:
To open the bracket, you’re not just lifting the weight of the TV—you’re leveraging that weight against the pivot, which means the actuator needs to overcome torque, not just vertical load.
🔧 Torque, Distance, and Actuator Force
Let’s define some terms:
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Torque = Force × Distance from pivot
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Moment Arm: The longer the distance between the pivot and the TV center of gravity, the more torque the actuator must overcome.
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The shorter the actuator arm (distance from pivot to actuator connection), the higher the required force.
Check the diagram below 👇
In this setup:
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Distance from pivot to the center of the TV = ~17"
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Distance from pivot to actuator attachment point = let's say 10"
So, the leverage ratio is ~1.7:1, meaning the force the actuator needs to exert is 1.7× the effective downward force from the TV.
If your TV weighs 60 lbs and sits 17" from the pivot, that's ~1020 in-lbs of torque, gives you ~102 lbs of linear force needed—and that's without accounting for friction, inertia, or safety margins.
✅ Key Design Considerations
To design the system safely and reliably:
1. Bracket Height
A taller bracket creates a larger moment arm. That increases torque. If you're mounting a tall TV, the pivot must be positioned carefully and reinforced.
2. Actuator Mounting Position
The actuator should be mounted as far from the pivot as feasible (within your ceiling space), which reduces required force. We have created a simple First class lever calculator here.
3. Actuator Force Rating
Choose an actuator with at least 25–50% more rated force than your calculated requirement to prevent stalling or burnout.
💡 For a 60 lb TV on a 35" bracket, an actuator rated for 1500–2000 lbs of force is a good starting point.
4. Speed vs. Force Tradeoff
Actuators with higher force ratings tend to move slower. Balance speed and power based on your needs.
5. End Stops and Limit Switches
Use built-in or external limit switches to prevent over-travel and protect your components. The Actuators come with these already built-in, so no need to worry about this. External limit switches could be added if desired.
🧰 What You Need
Hardware:
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Electric linear actuator (12V or 24V, with appropriate stroke length and force)
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Ceiling mounting plate
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Steel or aluminum TV bracket frame
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Heavy-duty pivot bolt
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Fasteners and supports
Electronics:
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Power supply or battery
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Rocker switch or wireless remote control
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Optional: programmable actuator controller
🛠️ Assembly Overview
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Build the bracket to the correct height for your TV.
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Install the pivot securely to a ceiling frame or beam.
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Mount the actuator at an angle that provides good leverage (further = better).
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Wire the actuator with a switch or controller.
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Test, fine-tune, and enjoy!
🎯 Final Thoughts
Building a flip-down TV lift isn’t just about hiding a screen—it's an engineering project where mechanical leverage and actuator dynamics come into play.
When done right, it's elegant, quiet, and rock-solid. But skipping the force calculations can lead to poor performance or even damage. Take your time, model your setup like a lever, and size your actuator accordingly.
Need help choosing the right actuator? Check out FIRGELLI Linear Actuators, or browse our TV Lift Systems for ready-made solutions.
