Helix Trainer Redesign
Enhanced Ergonomics and
Functionality for a Smarter Workout
The Helix Trainer is a unique standing exercise machine that uses circular leg motion to activate lateral muscles and improve balance, cardio, and strength. Our team at Lime Design partnered with Helix to reimagine the MC04 model—bringing a more ergonomic, feature-rich, and visually modern version to life. With a focus on comfort, usability, and minimal installation, we transformed this home and gym essential into a refined, user-centric piece of fitness equipment.
Timeline
4
product development phases and 2 phases of Marketing development was required for this project
200+
Hours of design & development went into this project
Services Used
Concept Development
We began by reviewing existing units and client feedback to determine key pain points in usability, appearance, and bulk. Our design goal: reduce visual weight, improve ergonomics, and integrate helpful features like storage, device trays, and display space. Working within strict dimensional requirements, we explored a range of layout concepts while preserving recognizable Helix design cues.
Our design team developed five distinct concepts. The early concepts explored broad visual themes and architectural direction. As the design progressed, key elements began to emerge, such as a vertically stacked control layout and a defining rear “H” panel that offered both structural identity and brand storytelling.
Human-Centered Research
Human factors were a core focus of this redesign. We analyzed hand grip positions, torso lean angles, and user interaction zones for comfort while in motion. Features were carefully aligned for ergonomic posture during high-rep workouts, and placed to accommodate a wide range of user heights and arm lengths.
Sketching & Design Concepts
We designed a new interface area to support digital displays, touch panels, and branding elements. Device trays for phones and magazines were integrated above the console, while utility zones below the user line of sight housed a towel rack, compartments for keys and random items, and a water bottle holder.
In parallel, we refined the overall geometry of the handlebar system, emphasizing rubberized grips with contrasting accents. We also evolved the design language with a stylized “H” motif on the rear, a rugged detail that became the visual centerpiece of the entire machine. This H-frame not only reinforces the upper structure but acts as a built-in brand element.
Concept Refinement
With feedback from stakeholders, we narrowed down features from multiple directions into a unified final design. One of the critical upgrades was a display zone set at a 5° angle for better readability and interaction. Utility features like the universal tray, cellphone holder, and heartbeat sensors were merged cleanly into a coherent, intuitive layout. Rubber grips were shaped and positioned for both support and comfort, while overmolded accents added a premium touch.
3D Modeling
Refined sketches were translated into CAD, where full surfacing and component layout took place. This stage defined the overmolded zones, ergonomic grip transitions, and graphic placement with manufacturing precision. CAD modeling allowed us to plan for enclosure details, draft angles, and hardware interfaces, ensuring that the aesthetic updates remained practical for prototyping and production.
Concept Refinement
With feedback from stakeholders, we narrowed down features from multiple directions into a unified final design. One of the critical upgrades was a display zone set at a 5° angle for better readability and interaction. Utility features like the universal tray, cellphone holder, and heartbeat sensors were merged cleanly into a coherent, intuitive layout. Rubber grips were shaped and positioned for both support and comfort, while overmolded accents added a premium touch. Below, you can see the design evolution Helix went through as we progressed from Concept 1 to Concept 5.
Concept 1
Concept 5
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Are you an inventor with a groundbreaking idea, but unsure of how to turn it into a reality? Look no further! Our product development firm specializes in partnering with inventors like you to bring innovative concepts to market.
Get
Started
Today
- All Information Is Kept 100% Safe & Confidential