CD-01 Campbell Downs
Project 01 · CAD + Analysis

Multi-Station Fitness Rack

Structural design for a compact residential gym rack integrating pull-up, dip, and leg raise stations.

Assembly CAD Static FEA Fatigue A36 steel
Isometric CAD model of the multi-station fitness rack
Consumer-grade rack sized for a home footprint: 86 in tall, 45 in wide, 60 in deep.

Design targets

  • Support a 250 lb user load
  • Global factor of safety target of 1.5
  • Critical structural FOS target of 2.0
  • Minimum 78,000 loading cycles

Load cases

  • Balanced pull-up
  • Single-arm pull-up
  • Dip station loading
  • Leg raise station loading
86 inOverall height
45 inWidth
60 inDepth
A36Steel frame

CAD views

The assembly was modeled as a complete home gym station before any simulation.

Front CAD view of the fitness rack
Front view showing pull-up bar, dip arms, and backrest.
Side CAD view of the fitness rack
Side profile with base rails and bracing.

FEA-driven iteration

Failure mode → redesign → validated result.

Initial dip-load factor of safety plot
Initial dip-load FOS: below target near supports.
Updated dip-load factor of safety after reinforcement
Updated dip-load FOS after structural reinforcement.
Asymmetric pull-up factor of safety plot
Asymmetric pull-up identified upper-arm weakness.

Design response

Added rear bracing and a front support/step to distribute load into the lower frame. The upper arm material thickness was then doubled to resolve the single-arm pull-up case.

FEA Design iteration Fatigue validation