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Experience Superior Insulation.

The future of Hot Tub Covers; Why Insulation Matters

Traditional hot tub covers often fall short when it comes to retaining heat. Over time, foam covers absorb water, become heavy, and lose their insulating power—leading to higher energy bills.

The Patent Pending AIRCAP 1™ hot tub cover changes the game. Engineered with our AirLoc™ advanced heat welded drop stitch technology, The AIRCAP 1™ delivers unmatched insulation, keeping your hot tub hotter for longer and your energy costs lower.

How The AIRCAP 1™ Outperforms Traditional Covers

1. Maximum Heat Retention

Drop Stitch Construction: Unlike foam, our high-pressure woven core resists waterlogging and maintains its insulating properties for years.
All-Weather Performance: Our Patent Pending AirLoc™ airtight design forms a superior thermal barrier, minimizing heat loss even in harsh climates.

2. Efficient

Efficient Insulation: Less heat escapes, so your hot tub maintains your desired temperature more efficiently—meaning less costs and more relaxing.
Consistent Warmth: Enjoy spontaneous soaks without the frustration of water temp spikes.

3. Lifetime Energy Savings

Lower Utility Bills: By reducing heat loss, The AIRCAP 1™ can cut your hot tub’s energy consumption by up to 30%* compared to aging foam covers.
Long-Term Value: Traditional covers degrade quickly, requiring frequent (and costly) replacements. AIRCAP 1's™ durable design means fewer replacements and more savings over the life of your spa.

Illustration of sealed drop-stitch AIRCAP hot tub cover preventing moisture ingress and staying lightweight

The Cost of Poor Insulation

Cover Type

Avg. Annual Energy Cost

Replacement Cycle

5-Year Total Cost*

Traditional Foam

$400-$600

3-5 years

$2,000+

The AIRCAP 1™

$280-$420

7-10+ years

$1,400

*Estimates based on average U.S. energy rates and typical hot tub usage. Actual savings may vary.

Insulating Properties of The AIRCAP 1™ vs. The Competition

The industry standard OEM cover, which is the cover provided to you with your new hot tub purchase is a 1LB density cover. Manufacturers send the least dense (cheapest) cover to cut costs. A 1.5LB cover is considered to be an upgrade and likely what you would typically buy from a retailer/online after the original cover failed.

Hot Tub Foam Cover Insulation:

Foam density is a measure of how much material is packed into a given volume, usually expressed in pounds per cubic foot (lb/ft3). Here's a breakdown of the differences between foam densities of 1LB, 1.5LB, and 2.0LB:

1LB Foam Density:
● Weight: Lighter, with 1 pound per cubic foot.
● Feel: Generally softer and less supportive.
● Durability: Lower durability; tends to wear out or compress over time more quickly.

1.5LB Foam Density:
● Weight: Middle ground, with 1.5 pounds per cubic foot.
● Feel: Offers a balance between comfort and support. Not as plush as 1LB but not as firm
as 2LB.
● Durability: More durable than 1LB foam but not as long-lasting as higher density foams.

2.0LB Foam Density:
● Weight: Heavier, with 2 pounds per cubic foot.
● Feel: Firmer and more supportive. It's less likely to snap, break or compress under
weight.
● Durability: Higher durability, withstanding more wear and tear over time.

It is very important to understand the density of the foam used and its water absorption properties. The less dense the foam, the more air is in the foam and therefore the more water can be absorbed significantly lowering the original reported insulation benefits. A 1LB foam cover will absorb more water than a 1.5LB cover and a 2LB will absorb the least amount of water because it is the most dense material with the least amount of air.

aircap hot tub cover drop stitch cross section

AIRCAP 1™ Core With Patent Pending AirLoc™ Heat Welded Technology

The AIRCAP 1™ and Dead Air Space Insulating

The best way to understand dead air space insulation is to think of multi pane windows. Dead air space insulation is a method of trapping air between two spaces to create insulation. In practice, it's difficult to achieve a completely sealed dead air space, which makes it an imperfect insulator, however we are able to attain a dead air space within The AIRCAP 1™.

How it works
● Air is a great insulator if it's kept still, similar to the windows in your house.
● Engineered with our AirLoc™ advanced heat welded drop stitch technology

Real-world application
● Dead air space insulation is often used in double wall construction.
● It's also used in storm doors and windows, where the air is trapped between panes of insulated glass.

Foam Covers vs. The AIRCAP 1™

Foam covers provide good insulation when new, new needs to be stressed and understood because from that day on, the foam cover's insulating properties are dropping fast. After a year, when the cover has absorbed 1-5 lbs of moisture the insulation has been cut in half and by the 3-6 year point it is providing at, or near zero insulating value at which time the consumer should be replacing it. The AIRCAP 1™ designed with a 3” core will maintain it's R-Value for the life of the cover which is expected at 5-10+ years.

Forty years of real world studies have proven that the foam cover begins failing immediately, sacrificing insulation whereas, the AIRCAP 1™ will never absorb moisture and it will maintain its insulating properties in a far superior manner compared to traditional foam hot tub covers.