How a Hot Tub is Made
The Rotary Moulding Process
The cast aluminium mold for a hot tub is designed
and made by a team of Computer Aided Designers at a cost of over £80,000
to ensure that the inside of the hot tub is ergonomically perfect
for the human body. The heavy aluminium mold now loaded with polyethelene
granules is mechanically loaded onto a tri axis arm ready to be baked
in a 30 cubic metre computer controlled gas flow oven. This process
will take around one hour at over 350 degrees centigrade constantly
rotating on three axis so that all of the polyethelne will adhere evenly
to the inside of the mold.
Unlike injection molding
this process ensures there are no weak points within the structure
and maintains a constant polyethelne thickness throughout meaning
rotationally molded hot tubs are some of the strongest in the industry.
Once the cooking process is complete, the mold will be removed from
the oven and cooled for a further hour using water and air jets. This
cooling process is a vital part of the process to allow the chemical
bonds in the polyethelene to bond together before removal from the
mold.
Once the hot tub is cooled it is removed from the mold using pneumatic
air jets it is carefully inspected by a quality control manager for
any imperfections that may have occurred in the rotational molding
process. If any irreparable imperfections are found the tubs life will
end there and it will be ground down to be remolded again.
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