AIRCAP 1™ X-Small (Fits 80"-82" Spas) Deep Grey™

Name: AIRCAP 1™ X-Small (Fits 80"-82" Spas) Deep Grey™
Brand: thrml.
SKU: AC6000
Price: 1195.00 USD
Availability: InStock

$1,195.00 USD

Includes the pump, three Ziptech™ skirt depths and four keyed locking tie-down straps.

Free U.S. shipping — shipping policy.

All sizes

XX-Small · 77″–79″ X-Small · 80″–82″ Small · 83″–85″ Medium · 86″–88″ Large · 89″–91″ X-Large · 92″–94″

Not sure which size? Measure with SureFit™ · Warranty

Still weighing foam against foam-free? Every hot tub cover alternative, compared.

✓ Free shipping: ships in 1–2 business days, usually arrives 3–5 business days after that
✓ 3-year warranty · Secure checkout

Available in over 100 authorized hot tub showrooms across 32 states. Want to feel the weight and check the fit first? Find a dealer near you.

The AIRCAP 1™ X-Small fits square spas that measure 80" to 82" on the longer side (such as an 81" x 81" spa); sides within 1" still count as square. It is a foam-free replacement hot tub cover: welded drop-stitch air construction with AirLoc™ insulation, no foam in it, so it weighs 35 to 40 lb, never absorbs water, stays that weight for life, and one person can handle it. Color: Deep Grey™. Engineered to comply with ASTM F1346-23. Not for rectangular, round or oversize spas.

The Spa Fitter lists 129 models across 28 brands in this band. QCA Spas has the most, fourteen, all on its 82" square shells: the Day Dreamer, Dream Weaver, Tranquility, GT-289 and GT-350, plus versions QCA built for Home Depot and Lowe's such as the Sardinia and the Salerno. DreamMaker Spas has twelve, and Dynasty Spas and PDC Spas ten each. DreamMaker's include the Cabana 2500L and 3500L and Crossover 730L and 740L at 80", and the Comfort 2300L at 82". DreamMaker also sells Suite versions of most of these, which add steps and a cover to the same spa; the shell is unchanged, so a Suite takes the same X-Small as the standard model. Dynasty Spas' Bay Bliss, High Tide and Serenity Cove are 82", Hydropool's Serenity 4500 and 6600 are 80", and Garden Leisure's GL753L, PDC Spas' Malibu and Denali and Pinnacle Spas' Radiance and Valaris measure 82".

Size from the longer side. A shell that measures 82" one way and 81" the other is still square for fit purposes and takes the X-Small. A reading that falls between two sizes rounds up: 82.5", for example, takes the Small. Because the cover is built to overhang its band slightly, even at the top of the band (that is how a cover is meant to sit), an 82" spa is an X-Small, not a Small; the Small starts at 83". In the carton: the cover, three Ziptech™ modular skirt sizes so you can zip on the one that matches your cabinet, the pump, and four keyed locking tie-down straps. One person can unbox, inflate and fit this lightweight hot tub cover.

The big US foam-cover sellers' own pages list dry weights of 35 to 55 lb for custom foam covers and describe the cover getting heavy as the first sign it is failing. The AIRCAP 1 is a hot tub cover that doesn't absorb water because there is no foam in it to absorb anything; the insulation is air held between welded drop-stitch fabric layers. It is 35 to 40 lb on the day it arrives and the same on the day you replace it.

This foam-free hot tub cover costs $1,195 with free shipping to all 50 US states and ships in 1 to 2 business days. You have 30 days to return it, with no restocking fee (buyer pays return shipping), and it carries a 3-year limited warranty. Confirm your size on the Spa Fitter, the brand-by-brand fit index on thrmltech.com (1073 models across 60 brands, with the size each takes), or measure with the SureFit™ guide on the same site. Available in over 100 authorized hot tub showrooms across 32 states.

Product features

Welded drop-stitch construction — the same engineering as a premium inflatable paddleboard
Never absorbs water: no waterlogging, no gradual weight gain, no mid-life sag
Ziptech™ modular skirt system — three skirt sizes included for a custom fit
Engineered to comply with ASTM F1346-23 as a manual safety cover
Patented

Materials and care

Rinse with a garden hose and mild soap; pressure washing is not recommended. Avoid solvents and abrasive cleaners
The cover never absorbs water, so there is no seasonal dry-out — clean and go
Full care and inflation instructions: download the AIRCAP 1™ manual

What's in the box

AIRCAP 1™ cover
Three Ziptech™ skirt sizes
Pump
Four keyed locking tie-down straps

View full details

AIRCAP 1™ X-Small FAQ

What size hot tub does the AIRCAP 1™ X-Small fit?

The AIRCAP 1™ X-Small fits square hot tubs measuring 80"-82" across the top. Measure your spa side to side across the top of the cabinet. If your measurement falls between two sizes, round up — an oversized cover overhangs slightly, which is how a spa cover is meant to sit, while an undersized one will not seal along the edges.

Does the AIRCAP 1 absorb water like a foam cover?

No. The AIRCAP 1 uses an AirLoc air-cell core rather than foam, so it does not absorb water. It will not gain weight or lose insulating value over time the way a waterlogged foam cover does, which is the usual reason a spa cover has to be replaced.

How much does the AIRCAP 1 weigh?

35–40 lb depending on the size, and it stays at that weight: the AirLoc air core cannot absorb water, so there is nothing inside to get heavier. Foam-cover sellers list new covers at 35–55 lb dry, and a waterlogged one is commonly reported at 100 lb or more.

How much does the AIRCAP 1 cost?

The AIRCAP 1 costs $1,195 in every size, including the pump, three Ziptech skirt depths, and tie-down straps. A foam cover typically runs $400–700 and needs replacing every 3–5 years; the AIRCAP 1 has no foam to waterlog.

Does the AIRCAP 1 ship free?

Yes. Shipping is free to all 50 U.S. states, including Alaska and Hawaii. Orders ship in 1–2 business days and typically arrive 3–5 business days after that; Alaska and Hawaii can take a little longer.

Do I need to measure the corner radius of my hot tub?

No. Rigid foam covers need a corner radius; the AIRCAP 1 does not. Two straight measurements across the top of the spa are all that is required.

What warranty comes with the AIRCAP 1?

Three years, or 36 months, from the date of delivery to the original purchaser, against defects in material and workmanship under normal use.

Can I return the cover if it does not fit?

Yes. Returns are accepted within 30 days of purchase, in like-new condition with all original parts included. There is no restocking fee. You are responsible for return shipping; if you request a prepaid label the cost is deducted from your refund. Refunds are normally processed within seven business days of the return arriving. Bought from an authorized retailer? That retailer's return policy applies.

How do I know which AIRCAP 1 size fits my brand of hot tub?

Look your spa up in the Spa Fitter, which lists the current models of every major manufacturer with the AIRCAP 1 size each one takes. If your model is not listed, the SureFit guide walks through the two measurements needed for any hot tub.

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This product has no reviews of its own. The merchant grouped it with related products, so the reviews shown are from across that group.

Awesome product, my kids don't complain about the cover anymore it fits and looks great, set up was super easy and took about 15 min total. Packaging was also great did not need a sharp object to release the AIRCAP and there was no Styrofoam.

My old foam cover had become completely waterlogged and I was tired of buying a new cover every couple years. I purchased the thrml. AIRCAP and the difference is night and day. Super lightweight, will never get waterlogged, and it looks great!

Great customer service still matters, and frankly, not enough companies deliver it anymore\. This company does, and that deserves recognition\.

Nice and lightweight

When I saw this online, I was so excited. For a reasonable price, I can cover my spa with a top that won't get musty. It stays light and easy to move, instead of getting waterlogged and heavy. It looks clean and it fits well. Installation was a breeze and we love it already!

It is incredibly rare these days to experience customer service that actually cares, that responds immediately and goes the extra mile to care for the customer. What this company has created in terms of an original and revolutionary product is nothing short of amazing. Do not wait to buy one. And if you need help, they'll be there every step of the way.

Great fabric. Loved the quick delivery