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BARLOG makes the XBAR3 fit for market entry

With protosys® rapid tooling and test laboratory to the finished fitness product

350 muscles are set in motion by the XBAR3 swinging bar in the human body. According to the manufacturer, “its design is reminiscent of the powerful swings of an eagle, which glides weightlessly through the air with an efficient effort” – and that is exactly the principle. The XBAR3’s handy handle allows for different workout variations, each with two or three fiberglass swing bars on the sides. In addition, the training level can be increased by changing the direction of swinging. Without much effort, the muscle areas are stimulated and trained. But it was a long way to get here, and it had to be done at top speed.

The task was a major challenge: in the shortest possible time, an easy-to-use, multi-functional training device had to be designed for market launch, while at the same time ensuring absolute safety for the user. Solution: protosys® technology for prototypes ready for series production. Injection molding is used to produce components from freely selectable thermoplastic materials in accordance with the previously calculated performance. The method in the form of rapid tooling enables fast and inexpensive results close to series quality. If changes to the component are still necessary, they can easily be made in our aluminum mold inserts and transferred to the later series tool. The hybrid technology used by BAHSYS to connect the fiberglass rods to the coupling mechanism promised maximum safety with the lowest manufacturing costs in series production right from the start.


At each stage of pre-series production, the various components were compatible with each other and each ended up on the test stand in the shortest possible time. In the test laboratory, theXBAR3 was tested for all important criteria. A special test rig was specially designed for this purpose, with the help of which the fitness equipment was tested for strength and durability.





The first result revealed a weak point on the handle. Thanks to testing during development in conjunction with geometry optimization, we were able to correct this quickly and cost-effectively using the protosys® process. After successful completion of the endurance tests, the suitability of the components for series production was also ensured. The sports equipment was thus able to be launched on the market within a very short time and is now not only successfully on the market, but also meets the high demands in terms of durability, intended use and comfort.




PS: protosys® Rapid Tooling is only one module in our extensive range of services for product developers. The same applies to The Test Lab. Take a look at our overview of all services.

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