Most products we all use are built in remote factories, using materials, equipment and processes that have become totally unfamiliar.  We started at the other end of the scale, with early hand-built prototypes from flooring joists, skateboard wheels, and angle iron.  Here’s a quick low-down on the current procedure:

  1. Airtrainers fabricated in Europe by a top team of engineers and metalworkers
  2. Design work completed in AutoCad with machine-readable files for automated manufacturing
  3. We use mild steel and aluminium, which go through a range of precision operations:
  • carriages cut and press-folded from a single sheet of mild steel
  • beams delivered in 7m lengths, cut to size, galvanised and tapped
  • folding mechanisms milled and assembled
  • benches hand-upholstered and printed using marine-grade vinyl
  • other components include top-end low-friction yachting pulleys, and the most robust handles on the market
  • custom cutting dies used for secure packing (we’ve come a long way from tape and bubble-wrap!)

We’ll post more details on fabrication in future.