CASE STUDIES
Manufacturing High-Demand Bicycles in a Pandemic
Client Overview
Sports Texas Inc. and the Power Cycle Innovation
Product Concept and Market Surge
Sports Texas Inc., the owner and designer of the Power Cycle—a custom stationary bike tailored for high-intensity interval training—had been developing and refining the product with RSP since 2017. As the Power Cycle’s first production order was placed in early 2020, the COVID-19 pandemic triggered widespread disruption to global supply chains and triggered surging consumer demand for bicycles and at-home exercise equipment, making materials suddenly scarce and highly sought after.
Supply Chain Management and Manufacturing Response
To navigate the unprecedented supply challenges, RSP leveraged its established supply chain expertise and strong vendor relationships to secure necessary materials and lock them in for on-time delivery, despite the rapid tightening of availability as gyms closed and consumer demand for home fitness equipment surged. In addition to supply chain coordination, RSP supported the Power Cycle project with prototyping and manufacturing services, including producing the plastic molded enclosure for the bike.
Collaborative Development and Prototyping
Sports Texas Inc.’s founder, Ed Coyle, expressed strong satisfaction with RSP’s prototyping capabilities, highlighting the responsiveness and detail-oriented approach of the RSP team throughout prototype development. Project leadership—including on-site coordination and vendor interaction—helped ensure necessary design adjustments were implemented correctly and efficiently.
Outcome and Client Perspective
RSP’s comprehensive services enabled Sports Texas Inc. to bring the Power Cycle to market even as pandemic-related supply constraints posed challenges industry-wide. When asked why they chose RSP over competitors, the company emphasized RSP’s capability as a one-stop partner capable of managing everything from supply chain and prototyping through production and logistics.