Custom sports equipment manufacturing
We manufacture, which means a dimension you impose, an apparatus that does not exist in any catalogue, or a replacement part needed ten years after delivery does not depend on a third party. Light In Fitness designs, industrialises and produces sports structures and equipment to order in steel, stainless steel and other metals, for indoor and outdoor use, and more broadly any metal part or structure made to your drawings: dimensions, loads, finishes and branding to your specification. Volumes run from a single piece to full production series.
What the workshop covers
Six complementary processes sit under one point of contact, which is what allows a complete assembly to be produced rather than a set of parts you then have to bring together yourself.
| Process | Capability | Typical output |
|---|---|---|
| Welded fabrication | Metal structures and welded assemblies in steel and stainless | Cages, racks, rigs, strength structures, indoor and outdoor apparatus, street workout stations, stainless furniture, heavy frames |
| Sheet metal and tube | Laser cutting of sheet and tube, CNC bending, rolling, wire work | Tubular chassis, benches, supports, apparatus, precision sheet metal and housings |
| Machining | Turning, milling, precision grinding | Shafts, pins, spacers, mechanical components, tight-tolerance functional parts |
| Plastic injection | Custom tooling, small and large series | End caps, handles, covers, stops, technical parts, trims and accessories |
| Brass foundry and bar turning | Casting, die forging, precision bar turning | Brass fittings and components, parts to drawing, associated machining |
| Finishing and assembly | Simple or complex assembly, kitting, indoor and outdoor finishes | Epoxy paint in your colours, weather-rated outdoor finishes, complete ready-to-install assemblies, custom packing |
Steel and stainless are the main materials, with brass and other metals available on request. Where equipment will live outdoors, the finish specification matters more than the structure: this is where a project either lasts thirty years or needs recoating every few seasons.
Working from your drawings, or without them
The normal route is that you send drawings or a written specification, and we carry out the technical study, cost it and produce to your specification. Where no drawings exist, we design the equipment from your requirement, and that design and engineering work is quoted and invoiced separately rather than absorbed into the unit price, which keeps the manufacturing cost transparent.
How a custom project runs
| Stage | Content |
|---|---|
| 1. Study and costing | Technical analysis, design work, detailed offer, based on your drawings or specification |
| 2. Industrialisation | Tooling launched, initial samples produced, quality validation before series release |
| 3. Production and inspection | Manufacture, assembly, in-process and final quality control |
| 4. Delivery | Shipment to your installations, to the quantity and schedule agreed |
The stage most often underestimated by buyers is industrialisation. On a one-off piece it barely exists; on a series it determines the unit cost and the repeatability of everything that follows, and rushing it is the usual cause of a first batch that has to be reworked. Initial samples exist precisely so that a dimension or a finish can be corrected before tooling is committed.
Quality, traceability and documentation
Manufacturing conforms to French, European and international standards, with in-process and final inspection. Material and production are tracked so that each batch is identified and traceable, which matters for anyone reselling into regulated environments or answering a public tender. Documentation supplied includes inspection and test plans, first article inspection reports and formalised manufacturing files. Prototypes and samples are produced quickly where a project needs validation before commitment.
For sports structures the applicable references are EN 957 and EN ISO 20957 for stationary training equipment, EN 16630 for freely accessible outdoor fitness equipment, and EN 1176 with EN 1177 where a structure is used by children. Steel structures carry a 20 year warranty and stainless steel carries lifetime cover.
Who commissions custom manufacturing
Gyms and fitness clubs and cross-training boxes commission bespoke rigs where a standard module length does not fit the building. Hotels, residences and campsites commission equipment matched to an architectural specification or a brand colour. Local authorities, municipalities and public sites, schools and universities, care homes and rehabilitation centres commission apparatus adapted to a specific user group or to a constrained space. Resellers and equipment manufacturers commission parts, assemblies and complete products to their own drawings, delivered kitted and packed under their specification.
Frequently asked questions
Can you manufacture from our own drawings?
Yes. Send drawings or a written specification and we carry out the technical study, cost the work and produce to your specification, with inspection documentation to match.
What if we have no drawings?
We design the equipment from your requirement. That study and design work is quoted and invoiced as a separate service.
What materials do you work with?
Principally steel and stainless steel, with brass and other metals on request. Finishes include epoxy paint in your chosen colours and weather-rated finishes for outdoor use.
Do you produce single pieces as well as series?
Yes, from a single piece to large production runs. Volume changes the industrialisation stage rather than the capability.
Discuss a custom project
Send us drawings, a specification or simply a description of what the equipment has to do, with quantities and target dates, and we will return a technical study and a costed offer. See racks and cages and street workout rigs, or submit a quotation request.