It's Not Just a Hot Tub, It's a ThermoSpa

Hot Tub Shell

Home Hot Tub Shell

Buying Guide, DVD & Brochure
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We only use Continuous Cast Acrylic (CCA) for many good reasons!

3 Spa Shell Colors

Our CCA includes UV inhibitors that prevent color 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.

The shell is the most important component in a hot tub!

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.


A checklist found on no other spa:

Specialized Acrylic Forming: Custom designed screens for each model assure a controlled thickness that enhances shell construction and minimizes failure. State of the art machinery with unique infra red technology adapts to each color eliminates color variation.
Opaque Barrier Coat: A proprietary ThermoSpas mixture protects the shell from aggressive resin applications that prohibit color variation in the acrylic shell. This protects the understructure and enhances the outer surface.
Fiberglass Matting: Very high fiberglass content matting is placed along the coping and other hard to reach areas. This helps prevent air bubbles from forming that could lead to defects and provides added structural integrity in key areas.
Vinyl Ester Resin Coat: Costly high-styrene resin improves the bonding between the acrylic and laminate ten fold. This osmotic barrier coat is only used by a select number of spa manufactures and luxury yacht builders to help prevent blistering.
The Perfect Final Coat: Most manufactures utilize inexpensive fillers with less than 15% fiberglass content. Sparta shells are built with 33% fiberglass and a Green resin technology that has absolutely ZERO filler. The result is a product that offers high structural integrity and is good for the environment.

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 spas more “earth friendly.”

Shell Process 1 Shell Process 2 Shell Process 3 Shell Process 4 Shell Process 5
Specialized acrylic forming assures a consistent thickness Multiple layers of unique laminate materials provide an impenetrable osmotic barrier Each layer is hand rolled to eliminate trapped air pockets Fiberglass matting and an opaque barrier coat add structural integrity Computerized trimming guarantees a smooth, even finished edge on the completed Sparta spa.