SOLUTIONS / CONTRACT MANUFACTURING

Fitness Equipment Contract Manufacturing

Welded frames, tube and sheet metal, motors and harnesses, powder coat and final assembly, from one manufacturer. You get a tested, boxed product. We deal with the fifty parts inside it.

✓

Tube, Sheet Metal and Welding In-House — CNC tube bending, fiber laser cutting to 20 mm, a 20-plus-person welding team with robotic cells.

✓

Built to Take a Beating — Fatigue and performance testing, custom jigs and go/no-go gauges, 100% in-line inspection.

✓

Mechanical and Electro-Mechanical — Strength racks and bike carriers, but also motorised training machines with harnesses, controls and functional test.

✓

Three Production Regions — Finished products built in China or Vietnam, with made-in-Vietnam origin for US-bound goods. Sheet metal parts from Mexico for North American programs.

Canadian-owned since 2005 · NDA before you send drawings

Practice tennis balls beside a motor drive assembly on a Komaspec fitness equipment production line

Fitness equipment contract manufacturing is the outsourced production of gym, training and sport hardware, where one manufacturer fabricates the frames and housings, sources the components, assembles, tests and packs the finished unit to the brand's specification.

Founded in 2005, Komaspec builds fitness and sport products as part of our turnkey contract manufacturing service: home and commercial strength equipment, motorised training machines, bike racks and carriers, and marine sport products, built in our factories in China and Vietnam, with sheet metal parts from Mexico.

Get a Free Manufacturing Review →
MANUFACTURING ACCOUNTABILITY

Fitness Equipment Is Simple to Design and Hard to Build Well

A squat rack is a few tubes, some laser-cut plates, hardware and a coat of powder. The difficulty isn't the design. It's that every one of those parts has to be right on unit 8,000, not just on the sample. A frame 2 mm out of square won't take an attachment. Weld spatter under the coating shows up as rust in a garage gym. A motor harness with one loose crimp comes back as a warranty claim.

When the tube comes from one supplier, the sheet metal from another and assembly from a third, nobody owns those problems. Each vendor's part met its own drawing. Komaspec was built to close that gap. We cut and bend the tube, laser-cut the plates, weld the frames, fit the hardware and motors, test the finished unit and pack it. One quote, one project manager, one company responsible for what arrives at your warehouse.

Send Drawings for a DFM Review →
Komaspec operator using an electric torque driver at an assembly workstation with a locating fixture
PRODUCT SCOPE

What We Build for Fitness and Sport Brands

Our fitness and sport work falls into four groups.

Strength and Gym Equipment

Racks, rigs, benches, plate-loaded machines and storage for home and commercial use. Welded steel tube and laser-cut plate, powder coated, with hardware kitted for assembly. Commercial units get heavier gauges and tighter frame tolerances.

Tube bending · Laser cutting · CNC bending · MIG and robotic welding · Powder coating · Assembly

Electrical and Motorised Fitness Products

Training machines with motors, controls and cabling, like the tennis practice machine shown on this page. We build the wire harnesses, integrate the motors and PCBAs and fit the housing.

Sheet metal · Plastic injection · Cable and wire harness · PCBA integration · Torque-controlled fastening · 100% electrical and functional test

Bike Racks, Carriers and Cycling Accessories

Hitch- and towbar-mounted bike racks, carriers and lock systems. Load-bearing weldments in tube and stamped steel, including pneumatic assist systems, powder coat for outdoor service. See the project snapshot further down.

Tube processing · Stamping · Laser cutting · MIG welding · Powder coating · Assembly · Fatigue testing

Marine and Outdoor Sport Products

Motorised kayak propulsion and water-sport accessories, where waterproofing drives the design. We've taken submersible products through IPX7 testing with injection-moulded housings, potted electronics and custom cabling.

Plastic injection · Potting · Custom cabling · Sheet metal · IPX7 testing

Technician holding a DC motor with crimped red and green harness leads for a fitness training machine
DC motor with wire harness, ready for mounting into a training machine chassis.
Assembler fitting internal components inside the black plastic housing of a tennis practice machine
Final housing assembly of a motorised training machine before functional test and packing.
Talk to an Engineer About Your Product
CAPABILITIES

Manufacturing Capabilities for Fitness Equipment

The processes fitness programs draw on, from raw tube to a tested, packed unit.

Process What we run Why it matters for fitness equipment
Tube processing CNC tube bending in 2- and 3-axis configurations, OD reducing and swaging, mechanical and laser tube cutting, drilling and stamping. Round and rectangular tube to 50 mm OD and 4 mm wall in carbon, stainless and galvanised steel, plus aluminium extrusion. Uprights, crossmembers, handles and safety bars are tube. Bending and cutting them in the same building as the welding removes the fit-up arguments.
Sheet metal and laser cutting 8 kW and 12 kW fiber lasers with auto-loading towers and a CO2 laser, cutting up to 20 mm. CNC press brakes from 24 T to 100 T including a robotic bending cell. PEM hardware insertion, deburring and tumbling. Foot plates, gussets, J-hooks, motor mounts and machine housings.
Welding 20-plus welders across TIG, MIG, laser and spot welding, three Panasonic robotic welding systems and an ABB robot cell. Welding jigs designed and built in-house. Robotic MIG for repeatable frame joints at volume. Jigs hold squareness so attachments fit every rack, not most of them.
Stamping Manual and progressive stamping on presses from 16 T to 200 T, with secondary machining, welding and finishing in the same building. Brackets, hooks, clevises and hardware plates at high volume and low piece cost.
CNC machining Turning with automated bar feeding, 3- and 4-axis milling, drilling, chamfering and threading. Pins, bushings, spacers, pulley axles and threaded inserts.
Plastic injection Seven presses from 130 to 650 T, overmoulding and insert moulding, ultrasonic welding, colour matching. Grips, end caps, housings, guards and covers matched to your colour standard.
Surface finishing Powder coating with RAL and Pantone matching, e-coating, zinc plating, anodising and polishing, all under our inspection plan. Colour matching keeps frames, plates and accessories consistent across a range, and the right finish keeps garage and outdoor gear from rusting.
Electronics integration Cable and wire harness production, PCBA integration, custom test fixtures and functional test. Motorised and connected fitness products leave configured and tested, not as a kit.
Assembly and kitting Six belt conveyors, six plate conveyors, twelve high-mix workstations and an open cell with mobile cranes for assemblies over 2.5 m. Riveting, stud welding and kitting stations. Final assembly of machines, or kitted hardware bags and part sets for installer or consumer assembly.
ENGINEERING INPUT

Designing Fitness Equipment for Manufacture

Our engineers review every fitness program before it's quoted, and the same six things come up. Here's what we look for. How DFM works at Komaspec →

Electric torque driver fastening a black powder-coated sheet metal plate to a tube section
01

Tube sections and wall thickness

Our tube bending covers tube to 50 mm OD and 4 mm wall. Larger structural sections can still be cut, welded and finished, but cost and lead time change. We'll tell you at RFQ which side of that line your design sits on.

02

Weld access and sequence

A joint that's easy to draw can be impossible to reach with a robotic torch once the neighbouring member is in place. We design the jig and the weld sequence together, and we'll suggest moving a gusset or splitting a weldment if that's what it takes to weld and inspect the joint properly.

03

Tolerances that matter versus tolerances that cost

Hole patterns for uprights and attachments need to be held tightly so accessories fit across the range. The overall length of a cosmetic cover does not. We flag where a drawing is tighter than the function needs, because that's usually where the cost is hiding.

04

Finish over wear surfaces

Powder coat on a contact point, like a J-hook or a safety arm, will chip. Where the design allows, we'll recommend a plastic liner, a UHMW insert or a plated part before the first sample comes back scratched.

05

Hardware and kitting

Retail fitness equipment ships partially assembled. Deciding early which sub-assemblies are built here and which fasteners go in the bag affects carton size, freight cost and how many support calls your customers make.

06

Motors, harnesses and test points

For motorised products we look at connector selection, strain relief, and whether the harness can be routed and tested before the housing closes. A test point you can reach on the line is worth far more than one you can only reach after disassembly.

LOAD-BEARING, PEOPLE-FACING

Testing and Quality for Fitness Equipment

Fitness equipment carries load, and people trust it with their bodies. Our quality process reflects that.

Fatigue and performance testing

For load-bearing products such as racks and bike carriers, we run fatigue and performance testing to your specification before release, and support third-party certification testing where required.

Custom jigs and go/no-go gauges

Built in-house for each program, so frame squareness, hole positions and attachment fit are checked objectively at the station rather than by eye.

100% in-line inspection and functional test

Every unit, not a sample. Motorised products get a powered electrical and functional test before they're boxed.

Digital QC records

Inspection plans are pushed to tablets on the line with acceptance criteria. IQC, PQC and FQC data is captured digitally, traceable to work order and batch, and exports to COC and FQC reports for your files.

Certification support: we've supported customers through product certification to CE, UL, FCC, VDE, CSA, ETL and KCC, with in-house and external laboratory testing. Explore our full Quality Management system →
Technician testing a control panel and wiring with a digital multimeter at a Komaspec test bench
Control board and harness check at the test bench.
PROJECT SNAPSHOTS

What These Programs Actually Look Like

Finished black motorised tennis practice machine with launch tube, manufactured by Komaspec
Finished unit: plastic housing with launch tube.
ELECTRO-MECHANICAL ASSEMBLY

Motorised Tennis Practice Machine

A ball launcher with a plastic housing, DC motors, internal wire harness and control electronics. We build the harnesses, mount the motors and boards on fixtures using torque-controlled drivers, and run a powered electrical test on each unit before final housing assembly and packing.

Processes Applied:
Wire harness · Motor & PCBA integration · Plastic housing assembly · 100% electrical & functional test
Towbar-mounted bike carrier with integrated rear lights and licence plate holder, manufactured by Komaspec
Finished unit: rear-mounted carrier with integrated lights and licence plate holder.
ELECTRO-MECHANICAL ASSEMBLY

Bike Rack with Integrated Lighting

A rear-mounted carrier with an integrated lighting system and licence plate holder. It looks like a rack, but the bill of materials runs to over 300 lines: extrusions, sheet metal, injection-moulded parts, cabling and electronics, all brought together in final assembly. Keeping a BOM that size on schedule is as much a purchasing job as a production one.

Processes Applied:
Extrusion · Sheet metal · Plastic injection · Cabling · Electronics integration · Assembly
GLOBAL PRODUCTION FOOTPRINT

Three Production Regions, One Program

Where you build fitness equipment changes its landed cost, its lead time and where it can ship from. Fitness gear is heavy and bulky, so freight and duty take a bigger share of landed cost than for most products, and country of origin matters more.

Guangzhou, China
4 factories · 110,000 ft²

Full vertical integration: tube, sheet metal, stamping, plastics, welding, assembly. Deepest component supply chain. Markets outside the US.

Laser cutting, CNC bending, welding, powder coating, hardware and assembly. Made-in-Vietnam origin for product supplied into the US.

Juárez, Mexico
20,000 ft²

Sheet metal parts: laser cutting, CNC bending, CNC milling. Nearshore component supply and spare parts for North American programs; finished fitness equipment is built in China or Vietnam.

One bike accessory customer runs exactly this split: China supplies Australia, Canada and Europe, and components move to Vietnam for assembly and US supply under a Vietnamese certificate of origin. Same engineering team, same quality system, same account manager. See our facilities →

Palletised Komaspec-branded cartons of finished goods in a warehouse ready for export shipment
Finished goods packed, labelled and palletised for export; we ship through our forwarder network or to your 3PL.
QUALIFICATION

Are We the Right Manufacturer for Your Fitness Line?

We'd rather tell you now than after two rounds of quoting.

We're a Strong Fit If:

✓

Your finished product is designed in tube, sheet metal or plastic, with or without motors and electronics, and there's an ongoing production program behind it.

✓

Volumes are medium to high, with variety: several SKUs, colours or configurations rather than one enormous run.

✓

You're a fitness or sport brand, an established SME or a funded startup moving from prototype to production, and you want DFM input rather than a factory that builds whatever is on the drawing.

There May Be a Better Route If:

✕

You need a handful of one-off sheet metal or CNC turned parts with no program behind them. Our sister platform Komacut quotes those online instantly.

✕

You want cast-iron plates, dumbbells or other commodity weight at the lowest possible unit price. That's not where our value sits.

✕

Your product is still a concept. We can support DFM, prototyping and troubleshooting, but we work from a design you own.

Not sure where you fit? Send it over and we'll tell you straight →

Fitness Equipment Manufacturing FAQs

Answers to common questions about our fitness equipment contract manufacturing services.

It's outsourcing the production of fitness, gym or sport equipment to a manufacturer that fabricates the parts, sources the components, assembles, tests and packs the finished product to your specification. In a turnkey model like Komaspec's, one company owns the whole build instead of the brand coordinating a tube shop, a sheet metal shop, a coater and an assembler.

Yes. We work from your drawings, 3D models and BOM. Every program gets DFM review at RFQ, drawing and sample stage, with written sample build reports. Tooling you pay for belongs to you.

 

Yes. Commercial units use heavier tube, tighter frame tolerances and more finishing control. We run different jigs and inspection plans for each rather than treating them as the same product.

Yes. Wire harnesses are made in-house, PCBAs are sourced from qualified partners and integrated by us, and every motorised unit gets a powered electrical and functional test on the line. Our electronics manufacturing and box build pages cover this in more detail.

There's no fixed MOQ. It depends on the part, the tooling and whether there's an ongoing program behind the order. We're set up for medium to high volume with variety. For low-volume or one-off metal parts, Komacut is faster.

Fatigue and performance testing to your specification, 100% in-process dimensional checks with program-specific jigs and go/no-go gauges, coating inspection before assembly, and a functional test on every finished unit. We also support third-party certification testing.

Finished fitness equipment is built in China or Vietnam. China offers the widest process range and deepest supply chain; Vietnam gives US-bound product a made-in-Vietnam origin. Our Mexico plant supplies sheet metal parts and small assemblies for North American programs. Programs can be split across regions, and we'll recommend a footprint with the quote.

GET STARTED

Start Your Fitness Equipment Program

Send us drawings and a BOM. You'll get a quote with DFM feedback attached: the cost drivers we can see, and what we'd change to bring the price down. No obligation, and no charge for the review.

NDA Before Drawings

Signed before you send files

DFM Feedback Included

Included free with every quote

Single Contact Window

Named PM from RFQ to ship