CS 1: Concept to Production

Objective: Development of a Thermoformed Personal Steam/Sauna Spa

Challenge:
The customer was purchasing a steam/ sauna spa from a Chinese supplier. Quality and supply chain issues negated any savings by sourcing in Asia. Additionally, the Chinese supplier’s Fiberglass reinforcement was rejected by the end user. Thermopro was asked to help design and manufacture a new prototype in 6 months for the Kitchen and Bath Show in Chicago.

Process:
McConnell Company took the lead in assembling a team to design and build the Spa. Thermopro was the selected thermoformer. Based upon the customer’s requirements, with numerous revisions, the team designed the parts, and subsequently built wood prototype tooling. Using a DR Acrylic Capped ABS, the parts were successfully formed, and reinforced with a polyurethane material.

Result:
The Spa was successfully assembled and displayed at the Kitchen & Bath Show in Chicago, winning recognition as “the Number 1 pick of the new generation of spa showers…”(The Wholesaler). The Wall Street Journal noted the product as among the most innovative at the show.