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How a Hot Tub is Made

by | Apr 22, 2021

If you are looking for a new hot tub and are curious about how it is built, keep reading! Our Arctic Spas® are handcrafted, inspected and tested throughout the build to ensure you get the best hot tubs on the market.

Our Arctic Spas® are created to withstand variable temperatures from the frigid cold winters to the heat in the summer. We have been designing tubs for over 20 years and focus our attention on making the toughest and most efficient hot tubs available. When you buy a hot tub from Arctic Spas® you are committing to a hot tub that lasts longer, costs less to operate, and is easy to maintain.

How do we do all this?


The Acrylic Hot Tub Shell

There is a lot that goes into making your hot tub and it all begins with a single sheet of acrylic that weighs around 200 pounds. We start forming the tub where we take a sheet of acrylic and load it into a vacuum former where the acrylic sheet is heated to 365 degrees.

This process turns the sheet into a gooey but still solid piece where the vacuum sucks it into the mold. By the time this sheet is stretched over the mold, some areas are as thin as paper.

Once the acrylic base is formed we move it into our fiberglass area where we add another inch of evenly sprayed fiberglass, adding about 700 pounds to the total weight of the tub. We must ensure a good structure comes from this process as it needs to withstand the pressure from over 1500 gallons of water. Testing for cracks along the way is crucial in this process to assure the tub can handle all this pressure.

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Hot Tub Jets

The spa is now moved into the trimming booth where we look for dimples that act as a guide on where to drill for the jets. The number of jets is optional so we are prepared to drill from 16 to 61 holes. Once these are cut we then insert the jets. The jets are installed using a plastic weld gun making an unbreakable bond that seals the jets to the tub.

The jets are tested by recirculating the water and look for leaks all around the jets. After this process, they insert the filter buckets. Once you take your tub home the water will get pushed through these filter buckets to ensure that it is always clean.

Now the tub is sent to the other end of the clear line station. The clear lines are the set of hoses that pump air into the water to give the jets their bubbles! This tubing goes through the manifolds then up into the jet.

After this, we add more hoses that are color-coded to indicate their purpose. An average of around 470 feet of hoses is used in each tub.

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Cabinets & Insulation

The cabinets that encase our spas are made from the finest solid cedar. This is then crafted to be the most aesthetically pleasing and functional cabinet possible. We inspect every cabinet closely after receiving them then add on the patented pressure stamped fiberglass floor. This floor is made out of pressed fiberglass that is engineered to withstand up to 3000 tons. Under all this pressure, the floor becomes incredibly dense and resilient to outside elements.

This fiberglass floor retains the heat while keeping the cold out. This process also ensures that no critters will be able to break through as well! This secure flooring eliminates the need for any type of foundation like concrete decking or blocks, creating an easy install.

Once the flooring is added, there is a healthy coat of foam insulation evenly sprayed over the casing. This is done by one of our technologically advanced robots, ensuring precision and consistency for all our tubs. This robot applies a coat of three inches of dense foam. With the cedar frame, this portion of the tub weighs around 600lbs.

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Once the foam is sprayed into the cabinets the tub moves to our install area. This is where we install the pumps, packs, and heaters. The combination of thick insulation and high-efficiency heaters takes the electricity cost of running this system down to an average price of a few dollars a day.

After everything is hardwired, the cabinet is flipped and married up with the shell creating a tub that weighs around 1600 pounds. We make sure that everything is nicely squared up and flip it over so it is right-side up.

With the base and the shell together the final connections are made, starting with the lights, control panel, and finally all the hoses and plumbing. This is where we do a final test to check for leaks and inspect all of our electrical systems. Over 136 inspections are done on each tub before they get sent off. After a passing grade, the removable doors are attached and it is ready to go.


The Final Product

As you can see we put a lot of care into guaranteeing you get the highest quality tub available. The final product that comes from this intensive process leaves you with an amazing hot tub that is not only aesthetically pleasing but the most efficient hot tub on the market.

If you are looking for a way to create the perfect oasis in your backyard, Arctic Spas® has you covered. Our manufacturing process allows for many possibilities when it comes to customization and promising constant quality. Talk to an Arctic Spas® representative today to learn more about our crafted hot tubs, and find one that will suit all your needs!

How do I know which is the right hot tub for me?

There are many questions to ask before buying a hot tub. Our Arctic Spas® hot tub specialists are always available to answer your questions and provide guidance on how to choose the right hot tub. Make an appointment for a personal or virtual consultation or download our hot tub buyer guide here.

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