The team behind the Hydro Wave’s success story has over 30 years of experience in the manufacturing and retailing of spas of the early days of gel coat to the next generation of acrylic vacuum forming to the latest technology of today in rotational molding.

What is rotational molding and why is it an advantage for hot tubs?
It is the process where powered plastic is heated, gelled and ultimately “Spun” on two axis to assume the shape of the spa. This high tech process affords incredible functionality and flexibility.

       Virtually any shape can be created in conformance with required tolerances and specifications. The natural G Forces of rotational molding ensure that the plastic spreads uniformly through out the mold until it is allowed to cool and harden this guaranteeing structural consistency and integrity. At the same time, the performance characteristics of plastic compound(s) used in this process inherently maintain incredible beauty and durability against impact, abrasion and the elements. As applied under rigorous demands of playground equipment to medical disposal containers, these plastic products look and perform well for years to come.

       Of all the possible materials for our spa construction, our extensive research resulted in the selection of Duralene, a high-linear polymer. The material is incredibly tough and corrosion-resistant. Our modern life interfaces with polymers every day. Some of its more apparent uses are in food packaging, interior and exterior auto parts, car batteries, refuse containers, caustic liquid drain openers, sporting equipment, infant car seats and children’s toys. Because high-linear polymers will not pit or corrode, its seamless surface prevents bacterial growth and is easily cleaned.

       Certain grades comply with FDA and USDA regulations, which make it ideal for sanitary uses, which is why it is used extensively in the medical profession.

       It is interesting to note that common polymer bleach bottles store minimum solutions of 25% chlorine and 75% water. This ratio applied to a 400-gallon spa would be equivalent to 100 gallons of chlorine. No conventional spa surface could withstand this concentration of chlorine, not to mention the danger to its user.

       The material is widely used in the defense and aerospace industries, in military vehicles, for example, and the space program for impact resistant missile containers. It is perfect for industrial uses such as gasoline tanks, chemical storage tanks and even acid tanks, not only to contain them but also to increase the safety factor in handling such corrosive and combustible materials.

       Duralene is more corrosion-resistant than stainless steel and has over ten times the impact resistance of conventional spa materials Far tougher than any other spa material, it resists gouging, scraping, and punctures.

       Another key feature of Duralene concerns its color and appearance. The surface is not just a veneer with inexpensive back up materials. The color pigments, with optimum amount of UV inhibitors, are molded all the way through the material, making it the most fade-resistant. Peeling, chipping, cracking, crazing, blistering or delaminating will not occur in Hydro Wave spas. They will retain their original appearance throughout their lifetime.

       Compared to other conventional spas this would virtually eliminate the possibility of damage that would require repairs. Should the rare event occur, repair is possible.

       As a spa material, one of the most important qualities of molded Duralene is its surface texture. In spite of the amazing damage resistance, the surface texture has a soft tender feel. When shaped into the smooth contours and curves of their distinctive liquid styling, Hydro Wave Spas produce the ultimate of sensual relaxation and pleasure.

       One of the first steps in our rigid quality control starts with the testing of each batch of resin. Before molding, the material is tested thoroughly to military and ASTM* specifications on special equipment.

       Proper molding of the duralene material into a Hydro Wave Spa is a must to produce a quality spa, unit after unit. Compared to conventional spa making. Duralene is Cast in curing layers until all the material is fused and the desired thickness is obtained. This allows thicker areas where needed, such as the floor and footwells, corners and other strategic stress points in the spa. With a uniform wall thickness and thicker corners and floor, a Hydro Wave Spa is virtually stress-free. Conventional spas use a vacuum-molding process, in which a precast or extruded sheet of heated plastic gets drawn into a fiberglass mold, stretching and thinning out in the stress points mentioned, that need the most material.

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