Product Design – Fitness System


The Background

The brief was simple;

“Design the most portable, multi-functional, light weight fitness system possible”

Concept Design

Our design team generated a wide range of ideas for initial review, utilising marker pen and digital sketching skills.


3D CAD Design

With the preferred concept identified, our 3D CAD Designers created fully detailed 3D CAD models of all components and assemblies.

Our Mechanical Engineers use Finite Element Analysis (FEA) to optimise any components that are subject to large stresses.


Prototype & Test

Our design team utilised Selective Laser Sintering (SLS) rapid prototyping for initial testing and refinement.

When the design was approved, we then built presentation quality prototypes using CNC machined production intent materials.   


With the Microgym I can get the client to do a full body workout using one piece of equipment instead of 5 or more.

Christopher Hunt – Personal trainer

Manufacturing Liaison

Moving towards manufacture, our team created design registration & patent images, liaised with a test house for CE marking, created engineering drawings in line with BS 8888, identified and liaised with manufacturers, and planned and implemented a crowdfunding marketing campaign.


The Result

The Microgym won the Merseyside Innovation Award in April 2019!

Discussions are currently underway with distributors in the USA and Europe.

All trade enquiries please contact


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