Pulse Fitness
Radnor Park
Greenfield Road
CW12 4TW

T: +44 (0)1260 294600

F: +44 (0)1260 299282


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There is a tradition of product excellence and innovation within Pulse Fitness’ in-house Product Design Team.

Based at Pulse’s UK headquarters, the entire research and development process is handled in-house under the leadership of co-founder Dave Johnson. Pulse is the only equipment provider that conceives, designs, builds, assembles and services its own innovative products in the UK for the UK market. With over 30 years experience producing industry-leading fitness equipment; Pulse is confident in the reliability, durability and effectiveness of its products.

Our Product Design Process

Project Planning


All products conceived at Pulse start life simply as an idea. This spawns a design brief which, once approved, is planned through a design input document/project plan.



It is important to Pulse to put the customer at the centre of the design process. This is done with regular reviews and the analysis of previous products and actively seeking customer feedback, which helps to inform the design process.

Conceptual Design


After the initial planning and research has taken place, concepts are generated and ideas refined. Sketching and story-boarding along with ergonomic standards are accessed and applied. In order to create appearance options; models are created and computer-aided design (CAD) prototypes are produced. From these initial ideas, provisional 2D GA (General Assembly) layouts are constructed.

Design Development


After the conceptual design phase, the design is looked at in more detail and the refining process begins. The design is controlled using various standardisation techniques, such as:

  • BS EN standards
  • Anthropometric evaluation
  • Inclusive evaluation (IFI)
  • Biomechanical consulting (BiMAL)
Colour Graphics


Once concept generation and presentations have been completed, concepts are developed for the livery of the range, in order to keep the products looking fresh and contemporary. Decals are designed and artworks produced to complete the overall scheme.

Detail Design


The refining process continues into the detail design phase, whereby the GA’s are finalised including all the agreed detailing. Data is transferred to suppliers and any modifications are made to the design to suit production needs or requirements.

Modelling Prototyping


During the design process the product needs to be evaluated and adjusted, thus models and prototypes are used to explore what the product will look, feel and act like in real life. Prototypes are tested and assessed by consultants from BiMal and IFI, leading to the prototype approval.

First Article


Once a product has been designed and manufactured a significant amount of work is carried out to ensure that effective and efficient tooling and assembly is in place. In order to check this, inspections take place on:

  • Sample parts – to ensure their integrity
  • Off-tool assemblies – to ensure that construction is of the highest quality
  • Three completed ‘articles’ – which are thoroughly tested and evaluated against the design criteria and required working tolerances


The product is subject to rigorous testing to ensure that it is fit for purpose and function as intended.

Service Regulatory Support


Pulse seeks to comply, not just with its mandatory legal obligations, but also with criteria from additional organisations, to ensure the highest industry standards for all clients. Approval and certification from the following bodies is sought:

  • Regulatory Submissions (BS ENs)
  • Product Certification (TUV, IFI)
  • Approvals (CE, UL & FCC)
  • Application For Patent Protection

Pulse also completes technical construction files for reference and future development, archives all documentation and even seeks medical certification in Germany.

Supporting Documentaion


Supporting documentation needs to be prepared once the design is finalised, such as:

  • Product user manuals (its 2D graphic design)
  • Technical service documentation
  • General service guides
  • Exploded parts diagrams
Mass Production


This is still not the end of the development process as the product has to undergo a final inspection/sign-off in the pilot-production stage. It is then introduced to Pulse’s customers at an official product launch event (such as IHRSA, FIBO or LIW). Once in mass production products then receive on-going support in order to further improve performance or reduce production costs.

Electronics & Technology

Pulse’s in-house Product Design Team imagined a world where fitness equipment was connected...

Within the last decade Pulse has used ‘design’ to transform itself, from being a commercial fitness equipment supplier into a technology solutions provider. Utilising in-house designed electronics, systems and software; has paved the way for a globally based digital network solution that empowers our clients and users alike.

Project Planning


As well as designing the product shell, all the electronics and hardware need developing before integrating them with the finished article.


FIRMWARE (Embedded)

Another technological aspect requiring design is the embedded firmware, this includes the graphic user interface (it’s 2D graphic design).

Conceptual Design


All software development occurs in-house and is supported in-house. Pulse is currently developing software for cloud based future solutions.

Design Development


As with the main product, all electronic developments need rigorous testing to ensure that they are fit for purpose and function as intended.