How Hydropool Swim Spa is Made

Hydropool has become one of the world’s top manufacturers of hot tubs and swim spas by focusing on quality. Hydropool’s reputation for reliability and innovative design has made it an industry leader. It now sells its products through retail partners in over 50 countries. If you were wondering how Hydropool has gained this reputation, it comes down to how the hot tubs and swim spas are built. Each unit requires over 20 hours of detailed handiwork by expert craftspeople. To show how Hydropool swim spa is made, we’ve put together this article.

Acrylic Shell

The shell of a swim spa is what holds the water and the swimmer. A good quality, long-lasting shell is an integral part of a quality swim spa. Hydropool swim spa shells are made from a single sheet of acrylic. Also known as polymethyl methacrylate, and commercially sold as Plexiglass or Perspex, this is the same material that’s used around ice rinks to provide the durable, see-through material that protects the crowds from flying hockey pucks. Acrylic is a synthetic polymer that is easily molded after being heated and comes in a wide variety of colours and designs and

Vacuum Forming

A single mold can be used repeatedly to create multiple swim spa shells. Once the mold has been designed, a sheet of acrylic is heated up and placed over the mold. A process known as vacuum forming is used to suck the flexible piece of acrylic over the mold and form it into the shape of the swim spa shell. When the acrylic cools it regains its solid, durable strength.

Shell Backing

While acrylic is very strong, it needs to be reinforced to be able to withstand the weight and pressure created by thousands of litres of water. The outside of the shell is coated in several layers of fibreglass and vinyl polyester resin to give it the strength to deal with such a large volume of water.


Swim spas are favoured over swimming pools by many northern-based swimmers because of their ability to be used in freezing weather. To prevent the swim spa water from freezing, the shell is insulated to help retain water heat. The fibreglass and vinyl polyester resin layer are sprayed with a coating that acts as both an insulation and a vapour barrier.

Trimming and Drilling

Once the shell backing has received its various coatings, the edges are trimmed to remove any excess acrylic, fibreglass and insulation. Holes are then precision drilled throughout the swim spa to house the water jets, drains, skimmer and other components. These holes are then filled with the corresponding components and sealed to ensure they remain waterproof.


Once all the holes of the shell are filled, the corresponding piping is attached and sealed. Each Hydropool swim spa contains up to 30 metres of piping to direct the flow of air and water into the shell and the mechanical components.

Mechanical Components

When all the plumbing is installed and tested for leaks, the mechanical components are installed. The water pumps, water heater, control panel, lighting and other accessories are fixed into place and connected with electrical wiring. Each component is fixed into place and checked for steadfastness.

Testing and Inspection

Hydropool spends a considerable amount of time testing and inspecting each and every hot tub and swim spa it manufactures. Swim spas go through a water test that lasts up to eight hours to ensure it remains watertight and all the various components work as they should. Once the unit passes inspection, it’s encased in its cabinet and wrapped up to be shipped to the customer.

To learn more about how Hydropool swim spas are made to last, download a free buyer’s guide.

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