Custom Gym & Fitness Equipment Manufacturers
Cardio Machine Manufacturing
THACO INDUSTRIES provides OEM manufacturing and processing services for cardio equipment. Its production capabilities include automated CNC machining, robotic welding, and high-durability powder coating to ensure structural integrity, corrosion resistance, and extended service life. All products undergo checks aligned to CE-compliant testing and inspection, ensuring safe and reliable performance in continuous high-load gym operations.
Power Racks Manufacturing
These modular training systems are manufactured using reinforced steel frames, robotic welding, and precise upholstery assembly. Each unit undergoes controlled functional testing to verify structural stability, smooth motion, and ergonomic comfort during continuous, high-frequency training.
Benches Manufacturing
Benches are engineered using CNC laser cutting and precision welding for structural accuracy. Steel frames undergo multi-stage surface treatment and durable upholstery integration, delivering long-term durability, safety, and ergonomic comfort for continuous operation in high-traffic commercial gym environments.
Selectorized Machines Manufacturing
Selectorized machine equipment uses steel frames and calibrated weight stacks with adjustable controls. These functional machines are trialed under repeated loading to maintain efficient functioning and safe operations.
Plate-Loaded Machines Manufacturing
Plate-loaded machines are manufactured using heavy-gauge steel structures and durable powder-coated finishes to withstand high-intensive training. Each unit undergoes structural load testing to validate frame integrity, operational stability, and long-term durability under continuous commercial use.
Free Weights & Accessories Manufacturing
The portfolio includes a range of gym accessories produced with CNC machining and protective coatings to extend service life. Drop and stress tests confirm that products hold up under daily use in multi-site training facilities.
Design Prototypes
At this stage, our engineers define each machine’s use, load capacity, and movement range. Using 2D/3D CAD tools such as SolidWorks or Inventor, we create virtual models and run load simulations under EN ISO 20957 and ASTM F2216 standards. Approved prototypes guide detailed drawings, BOMs, and physical test builds.
Material Sourcing
Gym equipment production starts with reliable inputs. Materials include steel pipes (ASTM A500/A513), steel plates (ASTM A36/A1011), and EN 10219/10210 structural sections, together with bearings, cables, pulleys, and fasteners. Each batch is supplied with an EN 10204 3.1 certificate and checked for grade and surface quality. This forms a solid base for the fitness machine manufacturing process.
CNC Machining & Welding
Tubes and plates are cut on fiber-laser or automatic saw lines, bent or pressed to shape, and drilled or tapped on CNC stations. Components are then joined using MIG/MAG (GMAW) or TIG (GTAW) welding per ISO 3834, WPS/WPQR, and ISO 9606-1 welder qualifications to secure dimensional accuracy and frame strength.
Surface treatment
After welding, parts are cleaned to SA 2.5 (ISO 8501-1) to remove rust and oil, then phosphated or pre-treated according to ASTM D3359 and ISO 12944 to enhance paint adhesion and corrosion resistance. When required, decorative or anti-rust plating follows ASTM B633/B456 standards. To enhance surface treatment, components then got ED coating to enhance corrosion-resistant ability.
Powder Coating & Finishing
Frames move through automated coating lines using powder coating or 2K wet paint. Coating thickness (DFT 70–100 µm), gloss, adhesion, and color are monitored to RAL specifications. Conveyor drying ovens control curing cycles to deliver a consistent, durable surface for long-term gym performance.
Assembly
Frames, arms, bearings, cables, and plastic covers are assembled on dedicated fixtures to ensure proper alignment. Each machine is then torqued, calibrated, and checked for movement, vibration, and noise to ensure stable performance and compliance with design specifications.
Quality Control Testing
Completed equipment undergoes final inspection with FQC and COQC documentation. Tests include dimensional verification, coating adhesion, and dynamic/static load testing per EN ISO 20957. For motorized units, electrical safety is confirmed, while NDT and periodic load tests validate weld integrity and frame durability.
Packaging & Delivery
Products are packed as solid or knock-down frames with PE covers, foam, and carton or wooden shelving. A final inspection compares each shipment to the BOM and attaches factory photos for the record.
Finished goods are shipped domestically and internationally under coordinated logistics. Documentation, container loading, and export records are maintained for traceability. This structured system ensures every order reaches clients safely, on schedule, and ready for installation at commercial gym facilities.
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Design Prototypes
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Material Sourcing
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CNC Machining & Welding
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Surface treatment
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Powder Coating & Finishing
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Assembly
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Quality Control Testing
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Packaging & Delivery
Gym Equipment Standards/ Certifications
Our fitness equipment programs align with EN ISO 20957 (EU) and ASTM F2216/F1250 (US) safety standards. Welding is controlled under ISO 3834 with ISO 9606-1 welder qualifications, supporting CE conformity where applicable.
THACO INDUSTRIES' Markets
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USA
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Canada
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Mexico
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Asia
FAQs
1. What information do you need from me to quote custom gym equipment?
2. What gym machines do you manufacture?
3. What is your typical lead time?
4. What is the minimum order quantity (MOQ)?
5. Do you provide custom branding (logo, colors)?
Read More
As a Vietnam-based manufacturer of OEM gym equipment, THACO INDUSTRIES leverages the capabilities of its Specialized Equipment Company, which operates advanced production systems for metal fabrication, welding, surface treatment, assembly, and quality control, supporting large-scale OEM manufacturing. Our portfolio covers commercial gym equipment such as cardio systems, power racks, benches, selectorized cable machines, plate-loaded units, and free-weight accessories, all designed for strength, safety, and longevity.
Our all-in-one manufacturing model allows our Gym & Fitness customers to streamline their supply chain, reduce coordination across multiple vendors, and accelerate time to market. At the same time, THACO INDUSTRIES offers flexibility for OEM and custom projects, adapting designs and production to meet specific brand and market requirements.
