Beautiful shells … that last forever

The shell is the most important We only use Continuous Cast Acrylic (CCA) for many good reasons! component in a hot tub!

Our CCA includes UV inhibitors that prevent the color from fading when exposed to sunlight. The surface of a ThermoSpas shell is smooth and luxurious to the touch, yet durable enough to resist stress cracking and easily withstands temperature changes from minus 50ºF up to 180º F. Other materials commonly used to construct a spa shell; gelcoat, OAS plastic, and inexpensive composite acrylics often fade over time and are susceptible to signs of aging. Those constructed merely of a vinyl liner are easily damaged and often require repair or replacement in a few short years.

Plus, CCA is a non-porous material which makes it simple to clean. ThermoSpas shells will look beautiful for generations to come and require very little maintenance.

In 2002 ThermoSpas formulated the ThermoBonding process that is used to manufacture every ThermoSpas hot tub. The result is an unprecedented 0% failure rate on tens of thousands of our spas built since that date. ThermoBond has allowed us to provide an industry-leading 20 Year Warranty. Always remember, pumps, heaters, filters, and other parts can easily be repaired or replaced—the shell cannot.

Spa Shell
  • Specialized Acrylic Forming
    State-of-the art machinery with infrared technology and custom screening helps assure a uniform thickness on every shell.
  • Opaque Barrier Coat
    A thin proprietary coating protects the understructure and prohibits color variation, enhancing the exterior beauty of the shell.
  • Fiberglass Matting
    We’re the only manufacture to apply fiberglass matting to the perimeter coping, foot well, and other high stress areas of the spa shell.
  • Vinyl Ester Resin
    Costly high-styrene resin creates an osmotic barrier coat that helps provide ten times more protection against blistering than standard resins.
  • Filler Free Resin
    Where nearly all competitors use a resin mixed with inexpensive fillers and only 13% fiberglass content, we guarantee two coats of a “Neat Resin” with NO fillers and a 33% fiberglass content.

Consistent Quality And Green Technology
A unique digital application program is used to monitor the thickness and resin/fiberglass content of each shell; guaranteeing optimum consistency and weight. Every shell is built with an unprecedented weight variance tolerance of less than 4% compared to well over 25% by most competitors. This provides high structural integrity and minimizes manufacturing flaws. Our structural shell design eliminates the need to use ozone layer depleting foam for support which helps keep our product more “earth friendly.”

Shell Process 1 Opaque barrier coat enhances the beauty of the spa.
Shell Process 2 Fiberglass matting adds structural integrity in critical areas.
Shell Process 3 Multiple layers of fiberglass and “neat resin” are applied.
Shell Process 4 Each layer is hand rolled to eliminate trapped air pockets.
Shell Process 5 Specialized acrylic forming assures a consistent quality.