Inside the Lab: How Springfree Makes the World's Safest Trampoline

At Springfree Trampoline, safety isn’t just a feature—it’s engineered into every millimeter of our design.

Behind the sleek looks and signature springless bounce lies a precise, methodical process built on decades of innovation, testing, and craftsmanship.

Our engineering team conducts over 1,000 daily tests, applying the same rigor found in world-class automotive and aerospace manufacturing. 

The result? A trampoline trusted by families and validated by engineers.

In this article, we’re peeling back the curtain and giving you an inside look at how Springfree Trampolines are made — showing how we go beyond industry standards to create a product that redefines what safety, quality, and longevity mean in backyard play.

Before that, though, let's discuss the traditional trampoline manufacturing process and why it's flawed.

How Springfree Trampoline Goes Beyond the Ordinary in Engineering

Testing is at the heart of everything we do.

It’s what separates Springfree from other trampoline manufacturers.

For us, testing isn’t simply about compliance — it’s about building a product that truly lasts.

Our goal is for every trampoline to not only reach its 10-year warranty but to far exceed it.

To achieve that, we’ve had to go beyond conventional industry standards and build quality into every layer of our design and manufacturing processes.

Our philosophy is based on hinshitsu no tsukurikomi — the Japanese concept of “building quality into the process.”

Instead of relying solely on inspectors at the end of the line to catch mistakes, every single operator becomes a quality expert.

Each person on the floor is responsible for ensuring that no defect is ever passed forward.

This approach eliminates the need for random sampling and ensures consistent, predictable excellence from start to finish.

We’ve learned that true quality comes not from policing errors after they happen, but from creating a process so robust that errors are unlikely to occur at all.

That mindset is deeply embedded in our culture — every worker is accountable, every step is traceable, and every trampoline reflects our collective pride in doing things right the first time.

The Premium Materials That Define Springfree’s Quality  

At Springfree, quality begins in the design lab.

Our engineering team in New Zealand is dedicated to designing a product that performs flawlessly.

When a trampoline is designed with precision from the start, it naturally produces consistent, high-quality results in manufacturing.

That commitment continues with our material sourcing.

We intentionally choose premium materials – sourced from across the globe -- before production even begins.

Think of materials like ingredients: the better the ingredients, the better the performance—and we only choose the best.

Here are some examples:

From there, we undergo three processes to manufacture our trampolines – IQC, PQC and CQC.

Let’s go over each in the next sections.

The IQC Process 

Once the materials arrive at our factory, we conduct thorough IQC (Incoming Quality Checks) on every batch.

For example:

1. Netting and fabric for elongation, UV resistance and colour fastness.

 

2. Steel frames undergo hardness testing to verify structural integrity.  

3. Packaging materials are tested using both the Edge Crush Test (ECT) and the Bursting Strength Test to ensure durability in transit.  

 

4. Painted components are checked for adhesion and corrosion resistance through salt spray testing, running up to 2,000 hours — four times longer than standard industry testing.  

 

The PQC Process

Next, the PQC (Process Quality Checking) process ensures consistency during production.

Instead of relying on random inspection, we use poka-yoke, the Japanese concept for mistake-proofing that makes it nearly impossible to produce a defect.

We use custom go/no-go gauges, 3D-printed jigs, and fixtures to verify that each component meets precise tolerances.

Every frame, net, and mat are checked 100%. If a part doesn’t fit in its jig, it can’t move forward.

 

That’s our built-in safeguard against imperfection.

 

 

 

The CQC Process

Our endurance testing takes quality to another level.

Every new design must pass our Three Million Bounce Test, which simulates a 165 lb jumper bouncing for 15 minutes a day over ten years, which is roughly equivalent to three million jumps.

The test runs continuously for a month. If a prototype fails to meet this benchmark, it’s rejected and redesigned.

 

The Benefits You Receive from Springfree’s Rigorous Engineering

Because every material and component has been tested, measured, and inspected at multiple stages, customers can expect everything inside to be in perfect order — no missing parts, no damage, no surprises.

For instance, our Packaging Rod Counting system ensures that every box contains precisely what it should, verified before sealing.

That attention to detail continues throughout ownership.

Our customers enjoy peace of mind knowing their trampoline has been tested to perform for a decade or more, through every season, in every climate, under any conditions.

The materials are chosen to withstand UV, rain, snow, salt, and extreme temperature swings without deterioration in safety or appearance.

Whereas other companies offer warranties that vary depending on the component, Springfree is the only trampoline manufacturer that warrants its entire product for 10 years.

In practical terms, this means:

Everything performs as it did on day one because every component has been validated far beyond typical use conditions.

Ultimately, our customers benefit from confidence that the trampoline they’ve invested in is not just safe, but built to last, backed by engineering discipline, rigorous testing, and craftsmanship that’s second to none.

Want to Learn More About Springfree’s World-Class Manufacturing?

Springfree’s factory – which has been called a “unicorn” by an executive from a major global retailer -- isn’t just another manufacturing site.

Rather, we strive to make it a model of lean thinking and continuous improvement.

Everything we do revolves around creating maximum value for the customer by eliminating anything that doesn’t add value.

This doesn’t mean cutting corners or racing to reduce costs.

It means removing waste, specifically the inefficiency, inconsistency, and variability that plague most traditional factories.

Every process, every jig, every operator movement is designed with precision and purpose.

Parts come off the line consistently, with minimal deviation, thanks to our kaizen (the Japanese word for continuous improvement) approach to continuous improvement.

We follow a strict Value Hierarchy when making improvement decisions:

This disciplined approach ensures that every Springfree Trampoline is produced in small batches using one-piece flow, with every operator empowered to stop and solve issues immediately.

It’s a culture where problems are addressed at the root cause, improvements are continuous, and excellence is the only acceptable outcome.

That’s what makes Springfree different.

Every material, every weld, every stitch reflects our commitment to deliver uncompromising safety, enduring quality, and genuine value for our customers around the world.

To learn more about Springfree Trampoline’s factory and manufacturing processes, visit dgshsourcing.com.