Efi Sports Medicine makes the whole with the help of SolidWorks

efiSportsMedicine has revolutionized the fitness industry by introducing tilt resistance training systems such as GRAVITY SYSTEM and TotalGym. Since its founding in 1974, the company has been focused on creating equipment that uses gravity and body weight to deliver effective workouts. As the brand evolved into efiSportsMedicine, the company aimed to redefine its image and expand into commercial fitness clubs and private gyms with innovative, modern designs. “Initially, we relied on basic drawing tools and manual fabrication,” recalls senior mechanical engineer Dan McCutcheon. “It was a very hands-on, almost DIY approach. When we adopted AutoCAD 2D, it helped, but to truly become a leader in the fitness equipment market, we needed to go further—into 3D design.” That’s when efiSportsMedicine turned to SolidWorks. The software's intuitive interface, powerful surface modeling, and advanced visualization features made it the ideal choice for their design process. With full integration of 3D components, the company could meet strict safety standards while streamlining manufacturing, cutting down on prototype costs, and accelerating time-to-market. One of the key benefits of SolidWorks is its ability to create complex and aesthetically pleasing shapes. This allowed efiSportsMedicine to move from traditional designs to sleeker, more modern products that stand out in the competitive fitness market. “SolidWorks gives us the freedom to experiment with curves, angles, and automation,” McCutcheon explains. “Fitness equipment needs to look good, and now we can design products that not only perform well but also attract attention.” Using the top-down assembly method in SolidWorks, engineers can visualize space, check for clearance issues, and simulate how parts will fit together. This level of precision helps avoid costly rework and ensures smoother development. Another major advantage of SolidWorks is its RealView visualization feature. It allows designers to present and validate concepts without building physical prototypes. “This saves time and money,” McCutcheon says. “We can show management and marketing teams what the product will look like before any real production begins.” Thanks to these improvements, efiSportsMedicine has significantly reduced its time-to-market by 50% and cut the number of prototypes from 10 to just one. The company has also expanded into new market segments, including commercial gyms and studio environments, where quality and design are highly valued. “We’ve built a product that’s not only functional but also elegant,” McCutcheon concludes. “With SolidWorks, we’re able to create surfaces and structures that would be nearly impossible to achieve with older methods. It’s a game-changer for our business.”

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