Efi Sports Medicine makes the whole with the help of SolidWorks

Customer Name: efiSportsMedicine

Website:

Industry Category: Consumer Products

efiSportsMedicine is revolutionizing the gym fitness system with the power of SolidWorks!

efiSports Medicine specializes in tilt resistance training equipment, offering a range of rehabilitation and fitness products under the GRAVITY SYSTEM and TotalGym brands. Since its founding in 1974 as TotalGym, Inc., the company has been developing equipment that uses gravity and a person's own weight to perform a variety of exercises. Over time, while maintaining its core focus on form and function, the company rebranded itself as efiSports Medicine, aiming to modernize its image and expand into growing commercial fitness clubs and private gyms, achieving strong market presence.

“Initially, we relied on basic drawing tools,” says senior mechanical engineer Dan McCutcheon. “We would bend and weld steel pipes by hand—very much like a garage setup. Later, we brought in AutoCAD 2D, but to truly become a leader in the commercial fitness market, we needed to move to 3D technology.” He continues, “Using 3D design allows us to elevate our systems, modernize our approach, and create more attractive and functional equipment for today’s market.”

efiSportsMedicine chose SolidWorks because of its intuitive interface, powerful surface modeling tools, and advanced visualization features. The ability to integrate all components in 3D was crucial for meeting safety standards, reducing manufacturing lead times, lowering prototype costs, and accelerating time to market.

Enhancing Aesthetics Through Complex Design

With SolidWorks' surface modeling capabilities, efiSportsMedicine can now incorporate intricate and visually appealing shapes into their designs. This shift has allowed them to transition from traditional TotalGym models to more modern, stylish products. “SolidWorks enables us to make real improvements to our product,” McCutcheon explains. “People want fitness equipment that looks good. We can now design with more curvature and higher levels of automation, creating standout products that capture attention.”

“By using the top-down assembly method in SolidWorks, I can see the available space, assess gaps, and consider how tolerances affect the fit,” he adds. “I can easily manipulate parts within the assembly.”

Accelerating Time-to-Market and Improving Communication

Since adopting SolidWorks, efiSportsMedicine has cut its time-to-market by 50% and reduced the number of prototypes from 10 to just one. “Design speed has increased by at least 50%, especially when building molds or working on complex assemblies,” McCutcheon notes. “It’s a game-changer.”

Thanks to RealView visualization in SolidWorks, McCutcheon can present and validate design concepts to management and marketing teams without needing physical prototypes. “This helps us evaluate the design thoroughly before moving forward,” he emphasizes. “That’s why we avoid costly overruns and rework.”

Expanding Into New Market Segments

The innovative designs developed with SolidWorks have helped efiSportsMedicine enter the competitive commercial fitness market, quickly establishing itself in studio and club segments. Despite high competition and price sensitivity, the company has carved out a strong position. “We need to add value through features, quality, and aesthetics to create an elegant product that stands out in commercial clubs,” McCutcheon says. “With SolidWorks, we’ve achieved success we wouldn’t have otherwise. Without 3D design, these complex surfaces wouldn’t be possible to produce efficiently or affordably.”