Why a Chop and Flue Gun Is Better Than Manual Application for Walk-In Baths
For any walk in bath manufacturer or walk in bath supplier, the way fibreglass (FRP) is applied to a bath shell directly affects strength, finish, and cost. A similar situation applies to a walk in tub supplier: the end customer depends on the product being reliable, watertight, and durable. When producing a walk in tub, two main methods are used to apply fibreglass reinforcement — manual hand lay-up and mechanical spray-up with a chop and flue gun. While both methods have their place, a chop and flue gun offers significant advantages that make it the preferred option for most manufacturers in the mobility bath industry.
Speed and Productivity
One of the greatest benefits of using a chop and flue gun is speed. A walk in bath manufacturer can apply resin and chopped glass fibre across large moulds quickly, which is crucial when producing high volumes of walk in tubs. Manual application, on the other hand, requires more labour and time, as sheets of fibreglass mat must be cut, positioned, and resin-brushed by hand. For a walk in tub supplier, faster cycle times mean shorter lead times and the ability to deliver products to customers more efficiently.
Consistency and Quality Control
Consistency is essential in the production of walk in baths. A walk in bath supplier depends on each unit being structurally identical to the next. With manual application, results can vary between workers, leading to potential inconsistencies in laminate thickness or resin distribution. A chop and flue gun, however, ensures that resin and glass fibres are applied evenly, creating a more uniform laminate. For a walk in bath manufacturer, this uniformity reduces weak points and helps guarantee every walk in tub meets high safety and performance standards.
Material Efficiency and Waste Reduction
Another advantage of a chop and flue gun is material efficiency. Manual lay-up methods often lead to resin-rich areas or wasted fibreglass mat. By contrast, a controlled chopper system deposits fibres precisely where they are needed, reducing waste and improving fibre-to-resin ratios. This matters to both a walk in bath manufacturer and a walk in tub supplier, since cutting down waste lowers production costs and helps make pricing more competitive. For a manufacturer shipping internationally, lighter and more efficient baths also reduce freight costs.
Ergonomics and Workforce Benefits
Hand lay-up is labour-intensive and physically demanding, often involving repetitive brushing and rolling. Over time, this can take a toll on workers. By contrast, a chop and flue gun reduces manual strain and automates part of the process. For a walk in bath supplier, this means healthier, more productive staff and a more efficient workshop. For a walk in bath manufacturer, better ergonomics also mean improved employee retention and reduced downtime.
Integration with Production Systems
A chop and flue gun integrates well with other production processes, such as gelcoat spraying and mould handling. This integration reduces bottlenecks and creates a smoother production flow for manufacturers. For example, once the gelcoat is applied, the chop and flue gun can quickly build up the laminate layers without excessive delays. This streamlines production, which benefits both the walk in bath manufacturer and the walk in tub supplier by shortening turnaround times and ensuring reliable scheduling.
Durability and Customer Confidence
End customers buying from a walk in tub supplier expect long-term durability, especially since walk in baths are purchased for safety, accessibility, and mobility needs. A uniform, high-quality laminate created with a chop and flue gun provides that durability. For a walk in bath supplier, fewer product failures mean stronger customer trust and reduced warranty claims. For a walk in bath manufacturer, it means maintaining a reputation for excellence and reliability in a competitive market.
Predictable Costs for Custom Work
Many customers require bespoke solutions — whether it’s a larger walk in tub for bariatric needs or a specially adapted bath for a unique installation. With manual application, estimating material usage and labour time is difficult, which can complicate pricing. A chop and flue gun makes the process more predictable, giving both the walk in bath manufacturer and the walk in tub supplier a clearer picture of costs. This predictability allows manufacturers to offer more competitive pricing while still safeguarding margins.
Why Manual Application Still Has a Place
It’s worth noting that manual lay-up has advantages in certain cases. Skilled technicians can strategically place continuous fibre mats in high-stress areas, or carry out small patch repairs where precision is more important than speed. However, for the majority of walk in bath production, especially for suppliers delivering at scale, the chop and flue gun provides superior results.
Conclusion
In the competitive world of mobility bathing, choosing the right production method matters. For a walk in bath manufacturer or a walk in bath supplier, the chop and flue gun provides faster production, consistent quality, improved efficiency, and greater worker safety compared to manual application. Likewise, for a walk in tub supplier, adopting this method means offering durable, reliable, and cost-effective products to customers who depend on them for independence and daily comfort.
Ultimately, while manual application still has its place for small repairs or niche customisations, the chop and flue gun remains the smarter choice for any manufacturer serious about delivering the highest standards in walk in tubs and baths.