— What's Different —
NOT Foam. NEVER Again.
Traditional foam covers begin failing the day you install them. Steam, UV, and chemicals slowly saturate the foam core — adding 50+ pounds of water, growing mold, and killing insulation performance. The average owner replaces their cover every 3–5 years. The AIRCAP 1™ eliminates the foam core entirely. Our drop stitch interior holds pressurized air between two layers of high-tensile fabric — no porous material, no moisture, no rot. Ever.
What Sets AIRCAP 1™ Apart from Other Foam Covers —
| Feature | Foam Cover | AIRCAP 1™ |
|---|---|---|
| Absorbs Water | Yes — up to 75 lbs+ | Never |
| Lifespan | 3–5 years | 10–15+ years |
| Weight Over Time | Keeps gaining | Stays 35–40 lbs |
| Mold Risk | High | None |
| Insulation Over Time | Degrades rapidly | Constant R-Value |
| Safety Certified | Varies | ASTM F1346-23 |
AIRCAP 1™ Core With Patent Pending AirLoc™ Heat Welded Technology
— Longevity —
Buy It ONCE
165,000 foam covers are discarded every month in North America alone. They can't be recycled — they go straight to landfill. The AIRCAP 1™ is built to last a decade or more, and when it does reach end of life, the drop stitch PVC can be mechanically recycled up to 7 times.
10 - 15 YEAR
Expected Lifespan
Versus 3–5 years for foam. No moisture absorption. No degradation. No surprises.
3x FEWER
Replacement Covers
Over the life of your hot tub, you may never need another cover. That's real long-term value.
5 YEAR
Manufacturer Warranty
We back it up. Foam covers offer 3 years. We offer more — because we know how it's built.
— Energy Efficiency —
KEEP the Heat. CUT the Bill.
A new foam cover insulates reasonably well. But within months, moisture begins infiltrating the core — and water conducts heat far faster than air. The cover that was helping you save energy is now actively working against you. The AIRCAP 1™'s AirLoc™ dead air space technology maintains a constant, sealed thermal barrier for the life of the cover. The R-Value you have on day one is the R-Value you have in year ten.
UP TO 50%
Less heat loss compared to an aging foam cover
Meaning your heater runs less, your energy bill drops, and your hot tub is always ready.
| Cover Type | Annual Energy | 5-Year Total* |
|---|---|---|
| Traditional Foam | $400–$600 | $2,000+ |
| AIRCAP 1™ | $280–$420 | $1,400 |
*Estimates based on avg. U.S. energy rates & typical hot tub usage. Actual savings vary.
— Built for the Elements —
We Tested EVERYTHING
Built using the same drop stitch construction as the most durable inflatable paddle boards on the market. Two layers of reinforced fabric, connected by thousands of tensile polyester threads, pressurized to create a surface that's rock hard, impact resistant, and impervious to weather extremes.
Hail
Versus 3–5 years for foam. No moisture absorption. No degradation. No surprises.
✓ Passed
Extremes
Scorching summer heat to below-zero temperatures. Patent pending PRVs manage internal pressure automatically.
✓ Passed
Load
A 4,000 lb truck drove over it. Heavy snow loads, jumps, standing weight — handled without issue.
✓ Passed
Rain
Sent to Seattle during the heaviest atmospheric river on record. Zero water absorption.
✓ Passed
AirLoc™ Technology —
Heat Welded Drop Stitch Construction
Every component is heat welded — not glued, not stitched. This means zero seam failures, zero delamination, and a fully sealed interior that maintains insulation integrity from day one to year ten.
ZipTech™ System —
Install in 15 Minutes. No Lead Times.
Our patent pending ZipTech™ zip-on skirt system means no 8-10 week custom order waits. Choose from 4 sizes that cover 90% of hot tubs, inflate, zip, done. Skirts are replaceable — even if your dog gets to one.
— AIRCAP 1™ by thrml.™ —
Ready to UPGRADE Your HOT TUB?
100% satisfaction guarantee. Free returns.
The AIRCAP 1™ ships to your door and installs in minutes.