Скачать или смотреть Modernizing a Premium Spa Line: From Stagnant to Scalable

When your product line has been stagnant for years, “a refresh” isn’t a surface-level exercise. It’s a design + manufacturing problem.

Mike Edey, R&D Manager at Blue Falls Manufacturing, shares how we partnered to modernize their premium spa lineup and move from design to production without the usual back-and-forth. With deep manufacturing knowledge baked into our process, we were able to skip the long explanations and focus on what mattered: building better spas, faster.

To de-risk the development, we produced a full-size, single-seat prototype to dial in the real-world ergonomics. Seat depth, seat angle, foot placement, and interference checks all had to be right before committing to an entire spa. From there, we tackled tight tolerances like jet recess locations, component elevations, and physical clearances, using VR to simulate the full-size hot tub experience and validate decisions earlier.

The big challenge? Designing 12 new models in a short timeline and launching them all at once to keep consistency across the entire product line, in time for a dealer seminar. We hit the schedule, delivered the lineup, and the results followed: after launch, Blue Falls saw nearly double the growth year over year, driven in large part by the new designs.

If you’re developing a product line and need a partner who can connect design, prototyping, and manufacturability, let’s talk.

Learn more about Onetwosix Design
Industrial design • Prototyping • DFM • Manufacturing-ready design
www.onetwosix.design

Chapters
0:00 Meet Blue Falls Manufacturing
0:18 The need for a modern spa line
0:39 Why Onetwosix
0:52 Full-size prototype for ergonomics
1:16 Technical challenges and fitment
1:30 Using VR to validate full-scale
1:43 Delivering 12 models on one timeline
2:04 Launch results

#industrialdesign #productdesign #prototyping #DFM #manufacturing #VRdesign #consumerproducts #