Kalamazoo’s collaboration with NuStep began in 2007. After considering several extruders in the area, NuStep chose Hydro for its experience in the fitness market, reputation in the industry, and precision with tooling and fixturing.
“Hydro’s respected throughout the industry for maintaining high quality extrusions while achieving maximum productivity and yields. Going with its Kalamazoo operations just made sense,” said Steve Borst, Account manager - Kalamazoo.
Kalamazoo extrudes the cross-trainer’s profiles through an 8” press then machines (which includes drilling and tapping) the T5 model’s aluminum seat rack and the adjustable handrails on the T5XR. All components must withstand the rigors of use, support up to 600 pounds, and allow a user a smooth, safe, and sturdy exercise session.
Alloy 6063 is used because it possesses moderate strength and has excellent finishing characteristics. Its corrosion resistance is exceptional and the grade is easily welded and brazed, and is heat-treatable as well. And since Hydro sources the aluminum through its North America cast house operations, Kalamazoo is able to assure NuStep of a consistent raw material supply.
The plant partners with a high-end supplier for, anodizing and silk screening. Once the finish meets quality standards, Kalamazoo sends the components to Ann Arbor, Mi for assembly by NuStep.
Hydro Kalamazoo
Hydro Kalamazoo’s extrusion press ranges from 15 to 300 tons. It can produce extrusions up to 7lbs/ft. and up to 8" wide. Complete machining capabilities include cutting, drilling, tapping, punching, welding, milling, shearing, turning, coining, and bending; as well as component procurement, kitting & assembly. Finishing capabilities include custom powder coat paint, clear and color anodize, and polishing and are outsourced to a reliable partner.
NuStep, Inc.
Headquartered in Ann Arbor, Mich., NuStep, Inc. is the manufacturer of the NuStep Recumbent Cross Trainers. Developed by exercise physiologists, these patented machines were designed to assist users with staying in motion regardless of their physical condition. For more information, visit www.nustep.com.
The Biggest Loser
The Biggest Loser challenges and encourages overweight contestants to shed pounds in a safe and recommended manner through comprehensive diet and exercise as they compete for a grand prize of $250,000.
The series provides contestants with challenges, temptations, weigh-ins and eliminations until the final contestant remains to claim the title of "the biggest loser." Each team works out under the supervision of professional trainers Jillian Michaels and Bob Harper.
Beyond the U.S., The Biggest Loser has become a worldwide hit appearing in over 90 countries and produced in 25 countries. Since its debut in 2004, it has grown to become a stand-alone health and lifestyle brand by developing tools and products inspired by the show and approved by its doctors and experts.
