ACRYLIC: THE PREMIER CHOICE FOR SPA AND BATH MANUFACTURING
Acrylic, or polymethyl methacrylate (PMMA), has emerged as a superior thermoplastic choice for crafting spas and baths, thanks to its excellent chemical resistance and remarkable durability under various weather conditions. Its versatility allows it to be thermoformed into complex shapes, making it the material of choice for high-end spa and bath applications. Delivered in sheet form, acrylic is manipulated through heating and molding to achieve the desired product contours.
THE PRODUCTION OF ACRYLIC SHEETING IS AN ART IN ITSELF, WITH THREE PRIMARY METHODS IN USE TODAY
- Cell Casting: This time-honored technique involves polymerizing methyl methacrylate between glass plates, resulting in a product of exceptional quality due to its high molecular weight. Despite producing superior acrylic, this method is the most costly.
- Extrusion: A cost-effective method that has gained global popularity, extrusion doesn’t reach the high molecular weight of cell casting, but it still yields a product satisfactory for a wide range of uses.
- Continuous Casting: A process that employs extensive, stainless steel belts to polymerize the MMA. This state-of-the-art method marries near-cell-cast quality with reduced production costs, though it remains more expensive than extrusion.
Leaders in continuous cast acrylic sheet production, such as Plaskolite and Trinseo/Aristech Surfaces , offer solutions tailored for the rigorous demands of spas and baths, which often involve prolonged exposure to heat, chemicals, and sunlight. The cross-linked sheets produced through continuous casting offer peak chemical resistance and superior thermoformability, along with the potential for creating unique colors and textures. In the realm of spa and bath manufacturing, continuous cast acrylic stands as the preferred material. However, it’s important to note that while acrylic excels in many areas, it does have limitations in terms of brittleness and impact resistance. For certain applications, extruded acrylics are employed, and two-layer sheets combining acrylic with another plastic, such as ABS, are also common. These variations cater to different manufacturing needs and cost considerations, with the trade-off typically seen in chemical resistance and thermoformability due to the lower molecular weight of extruded sheets. Acrylic sheets come in an array of colors, textures, and effects, including standard bath colors from brands like Kohler and American Standard. Trendy finishes such as granite-like surfaces, pearlescent, and marble colors have been mainstays in spa design for years. For the most up-to-date product selections, one should consult the manufacturers’ websites. The manufacturing of bath fixtures and spas from acrylic sheets involves heating them to approximately 500°F, then using vacuum forming to mold them into the final shape, followed by a spray application of polyester resin with fiberglass reinforcement for added strength and durability. This meticulous process ensures that the final product not only meets but exceeds industry standards for quality and longevity.