ProSledge
Modular Weight Vest
for Exercise
Design Focus:
Smart Strength Training Redesigned for Real Athletes
ProSledge approached Lime Design with a bold vision: to rethink the conventional weighted vest for modern strength training. Their mission was clear—develop a modular weight system that not only supports extreme resistance training but also integrates barbell functionality, customizable loads, and ergonomic flexibility for a diverse range of users. Our task was to transform this vision into a fully engineered, manufacturable, and performance-oriented product that could meet the demands of both elite athletes and everyday fitness users.
Concept Development:
Identifying flaws and refining them
We began with thorough benchmarking of existing weighted vests, identifying critical flaws in comfort, adjustability, load capacity, and barbell integration. From this, we initiated early sketches and functional studies to explore storage layout, weight modularity, and torso-fit ergonomics. Concepts A and B emerged—both offering strong, adjustable rigs with carry systems for over 150 lbs of weight. Concept A featured flap-pocket designs, breathable strapping, and segmented weight compartments. Concept B took a more sculptural approach, incorporating barbell cradles and a back-weight zipper interface for customization.
200+ hours of Design & Development
Use-Case Analysis:
Understanding user movement
Understanding how users move and train while wearing the vest was central to the design process. We incorporated rigid shoulders to aid weight distribution during heavy lifts, while still allowing freedom of movement. Interchangeable shoulder pads were tested for comfort and pressure relief, and the vest shape was contoured to accommodate both male and female body types. Hooks were added to concept variations for barbell resting points behind the neck during squats or presses, boosting utility without the need for gym racks.
Design Refinement:
Improving Function and Modularity
The vest’s modularity was key. We refined the weight pocket design to include removable sections for Molle or belt-style weights, with reinforced flap covers and quick-access adjustability via hook-and-loop closures. An optional belt system was integrated, allowing for additional weight loadouts and increasing the total load-bearing capacity up to 150 lbs. A molded plastic zipper system was introduced between vest layers, creating secure connection points for modular weight segments. Both Concept A and Concept B included multiple exploded views to illustrate how all elements assemble and detach with ease.
Ready to bring your ideas to life?
Let’s turn your vision into something remarkable. Whether you’re starting from scratch or refining an existing concept, we’re here to help.
