Services
Pre-Series and Mass Production
Once prototypes are approved, we move into pre-series sampling, producing a limited batch of parts under full production conditions. Pre-series samples are then sent to the client for final validation, including dimensional verifications, quality checks and performance evaluation. Based on client feedback, the process is refined to ensure full alignment on fit, function and finish.
After pre-series approval, production ramps up to mass manufacturing, strictly following validated process parameters and quality benchmarks to ensure every part consistently matches the approved reference.
Thermoforming and Stitching
Thermoforming and stitching processes are applied to technical components developed for sports equipment, where both performance and comfort requirements must be consistently achieved. These operations involve materials such as engineered foams, technical textiles and multilayer constructions, depending on the specific functional and ergonomic targets of the product.
During pre-series and mass production, forming, bonding and stitching operations are stabilized to ensure durability, structural consistency and repeatable quality in line with approved specifications.
- Thermoforming
- Stitching
- Ultrasonic welding
- High-frequency welding
- Precision shaving
Cosmetics
Surface decoration encompasses the various printing and transfer techniques used to apply graphics, logos and visual elements onto molded components. These processes are integrated into the production workflow after forming operations, with each technology offering specific advantages depending on substrate material, part geometry, production volume and durability requirements.
In sports equipment manufacturing, the selection and execution of the appropriate decoration method are defined according to material compatibility, expected wear conditions and visual standards. Every stage of the decoration process is managed in-house, ensuring controlled application, adhesion reliability and long-term durability of the finished surface.
- Sublimation
- Silk printing
- Tampo printing
- Digital printing
- Painting
- Gluing
Thermoplastic Production
Thermoplastic production represents the historical foundation of our industrial expertise. With nearly five decades of experience in manufacturing plastic components for sports equipment, we have developed a solid and continuously evolving know-how in process control, tooling integration and production efficiency.
Injection molding and related thermoplastic processes are applied across a wide range of geometries and performance-driven applications. Established manufacturing methods are combined with continuous process optimization to ensure consistency, repeatability and cost-efficiency at scale. At the same time, new technologies and alternative production strategies are evaluated and introduced when project objectives, functional requirements or budget constraints call for tailored solutions.
Composite Production
Composite materials combine two or more distinct materials to achieve enhanced mechanical and structural properties. In composite materials, the binding matrix and bearing fibers are expertly combined to achieve the best performance in terms of lightness, strength and durability. Each product has its own specific development history, and thanks to the high flexibility of composite materials, performance can be customized and refined for each application.
Our experience in producing high-performance sports equipment — including tennis rackets, archery bows, baseball bats and bicycle saddles — has built a solid foundation in composite manufacturing. Because material behavior and structural integrity are closely linked during production, process control and consistency are essential to ensure reliable and repeatable performance across volumes.
Assembly Lines
Modern assembly lines integrate manual operations and automated systems within a controlled production workflow. Process layout, cycle times and quality checkpoints are defined to ensure efficiency, repeatability and traceability across volumes.
We design and implement assembly lines according to product specifications, production targets and cost requirements. Each solution is developed considering the full manufacturing process, ensuring operational stability, scalability and long-term cost efficiency.