Pool Float

1. Design and Prototyping
- Concept Development: Create designs for shapes (e.g., animals, loungers, inflatable chairs) and features (cup holders, headrests, handles).
- 3D Modeling: Use CAD software to refine dimensions, buoyancy, and structural integrity.
- Prototyping: Produce a physical sample to test comfort, air retention, and durability in water.
2. Material Selection
- Primary Materials:
  - PVC (Polyvinyl Chloride): Most common; flexible, durable, and affordable.
  - TPU (Thermoplastic Polyurethane): Higher-end option for UV/chlorine resistance.
  - Vinyl: Lightweight and puncture-resistant.
- Valves: One-way air valves (e.g., Boston valves) for easy inflation/deflation.
- Safety Compliance: Non-toxic, phthalate-free materials meeting ASTM F963 or EN71 standards.
3. Cutting and Panel Preparation
- Die Cutting: Use steel dies or CNC machines to cut PVC/TPU sheets into float panels (top, bottom, sidewalls).
- Printing: Apply designs via screen printing (for bold colors) or digital printing (for complex patterns).
4. Welding and Assembly
1. High-Frequency (RF) Welding:
  - Use heat and pressure to fuse seams between panels, creating airtight seals.
  - Reinforce stress points (e.g., handles, valve areas) with double welds.
2. Valve Installation:
  - Attach valves manually or via automation, ensuring leak-proof bonding.
3. Accessories: Add D-rings, cup holders, or detachable shades using RF welding or adhesives.
5. Inflation and Quality Control
- Pressure Testing: Inflate floats to check for leaks, seam integrity, and valve functionality.
- Visual Inspection: Ensure print alignment, color accuracy, and surface smoothness.
- Weight Capacity Test: Verify buoyancy by loading weights equivalent to the float’s rated limit.
6. Deflation and Packaging
- Folding: Deflate and fold floats into compact shapes for storage.
- Packaging:
  - Retail: Use PVC-free polybags with eye-catching graphics.
  - Bulk: Pack multiple units in cartons for wholesale.
- Accessories: Include repair patches, inflation pumps, or care instructions.