The Symbio line combines advanced biomechanics, engaging user experience, and meticulous, purposeful design to create a new benchmark in premium cardio equipment.
In January of 2021 Life Fitness hired DiMonte group to assist with the detailed design of four new pieces of top of the line cardio equipment.
Upright Bicycle
Recumbent Bicycle
Elliptical Cross Trainer
Treadmill
At project handoff Life Fitness had developed rough industrial design models and a CMF spec, but had not yet given thought to how their cosmetic designs would break up into manufacturable pieces.
The 3D CAD files that I developed were able to transition seamlessly into production with little to no changes from the toolmakers.
Served as project leader for a multidisciplinary team of five designers and engineers at DiMonte Group, successfully managing timelines, deliverables, and client expectations.
Critical Design Decisions
Directed and implemented key design decisions that shaped product aesthetics, assembly, construction, and user perception, including:
Exterior Component Design – Developed detailed designs for injection molded plastic and die-cast aluminum enclosures
Seam Placement – Strategically positioned seams between panels for optimal functionality and visual appeal
Structural Considerations – Determined the placement and quantity of fasteners, structural ribs, and panel clips to ensure durability, rigidity and ease of assembly
Ingress Protection – Strategically designed seams to block or channel away moisture and cleaning agents, safeguarding sensitive electronics
Order of Assembly – Developed a logical assembly sequence, prioritizing serviceability, error-proofing (poka-yoke), and minimizing assembly steps
Advanced Surface Modeling
Utilized advanced SolidWorks surface modeling techniques to create smooth, curvature-continuous transitions between faces, elevating the product’s luxury visual appeal.
Design for Manufacturability
Provided actionable recommendations to enhance manufacturability, focusing on:
Welded Frame Design: Improved structural efficiency and assembly processes
Elliptical Linkages: Suggested modifications to optimize strength, reduce cost, and simplify production
Sub-Assemblies: Identified opportunities to streamline design for cost effective and scalable manufacturing
SOLIDWORKS EXPERTISE
Following the successful completion of a project, Life Fitness invited me to present a lunch-and-learn style lecture to a group of approximately 40 engineers and industrial designers. I gladly accepted, further strengthening the collaborative partnership between Life Fitness and the DiMonte Group.
My lecture covered key topics, including:
The use of master models – how they work and when to implement them
Essential settings for seamless cross-team collaboration
Advanced surface modeling tips and tricks
Strategies for building a stable and efficient feature tree
Thomas J. Schnell - Industrial Design Portfolio 