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
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.
Komaspec has done this for fitness and sport brands since 2005 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 own factories in China, Vietnam and Mexico.
Get a Free Manufacturing Review →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 →
What We Build for Fitness and Sport Brands
Our fitness and sport work falls into four groups. Product descriptions are generic on purpose; customer references are available on request under NDA.
Strength and Gym Equipment
Racks, rigs, benches, plate-loaded machines, storage and accessories for home and commercial use. Welded steel tube and laser-cut plate, powder coated, with hardware kitted for retail or installer assembly. Commercial units carry heavier gauges, tighter frame tolerances and more finishing control than consumer product. We run both on the same lines with different jigs and inspection plans.
Tube bending · Laser cutting · CNC bending · MIG and robotic welding · Powder coating · Hardware kitting · Assembly
Electrical and Motorised Fitness Products
Training machines with motors, controls and cabling, like the tennis practice machine shown on this page. We fabricate the sheet metal chassis and housing, build the wire harnesses in-house, mount the motors and boards, then run a powered electrical and functional test on every unit before it's boxed. PCBAs come from qualified partners; the integration and the test are ours.
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-mounted bike racks, carriers and lock systems. Load-bearing weldments in tube and stamped steel, with pneumatic or mechanical assist mechanisms, powder coat for outdoor service and fatigue testing before release. 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 · Overmoulding · Potting · Custom cabling · Sheet metal · IPX7 testing
Manufacturing Capabilities for Fitness Equipment
Vertical integration only means something if the list is real. This is what fitness programs draw on in our plants.
| 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. Powder coating in-house at our Vietnam plant; through qualified finishing partners in China and Mexico under our inspection plan. | Coating thickness and adhesion are checked before assembly, so a chipped bar gets caught here rather than in a customer's garage. |
| Electronics integration | Cable and wire harness production in-house, PCBA sourced from qualified partners, custom test fixtures, firmware loading 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. |
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 →
Tube sections and wall thickness
Our in-house bending covers tube to 50 mm OD and 4 mm wall. Larger structural sections can still be cut, welded and finished here, but they arrive pre-formed from a supplier, which changes cost and lead time. We'll tell you at RFQ which side of that line your design sits on.
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.
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.
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.
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.
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.
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 the housing closes and again before packing.
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.
What These Programs Actually Look Like
Motorised Tennis Practice Machine
A ball launcher with a powder-coated sheet metal chassis and housing, DC motors, internal wire harness and control electronics. We fabricate the sheet metal, 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.
Heavy-Duty Hitch-Mounted Bike Rack
Carries up to seven e-bikes and mountain bikes, with a heavy-duty pneumatic assist system. The assist mechanism needed design troubleshooting before it was manufacturable. We built jigs and go/no-go fixtures for 100% in-process QC and ran fatigue and performance testing before release.
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. Finished products come out of China or Vietnam; Mexico supports North American programs with sheet metal parts.
Full vertical integration: tube, sheet metal, stamping, plastics, welding, harnesses, 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.
Sheet metal parts and small assemblies: 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 →
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 tube or sheet metal 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.
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.
Signed before you send files
Included free with every quote
Named PM from RFQ to ship