Hot Tub Air Jet Rust Solution: Product Improvement from Supplier
In the hot tub industry, the durability and surface stability of accessories directly shape the end-user experience and the long-term reputation of a brand.
Recently, we received feedback from one of our clients: some spa air jet showed signs of rusting after extended use. Have you ever faced a similar challenge in your projects?
Fortunately, this feedback created an opportunity for us to further optimize our product design. The upgraded solution not only delivered a much better experience for end-users but also enhanced our client's brand value in the market.
In the following, we will walk you through the complete approach Hydrorelax takes to address and resolve such issues.
Identifying the Customer’s Concern: Rust on Hot Tub Air Jets
During long-term use of a hot tub, one of our client's end-users reported that several air jets had developed rust spots, with surface bubbling and peeling of the coating. While the jets still functioned properly, the appearance and overall user experience were clearly compromised.
For our brand-owner client, this was not only a disappointment in terms of customer satisfaction but also an added maintenance cost—something neither they nor their customers wished to bear. More importantly, it posed a potential risk to the reputation of their brand.
Determined to address the issue at its root, the client turned to us. Our professional customer service team promptly received and documented the feedback to ensure a fast and effective response.
Multi-Dimensional Root Cause Analysis: Product Attributes + Environmental Factors
Once the issue was reported, and the Hydrorelax product team quickly analyzed the phenomenon and concluded that it was most likely due to two main reasons:
Product Attributes (Internal Factor)
In the early design, the spa jet covers were produced with a standard electroplated finish.
While electroplating can provide short-term protection, prolonged exposure to water and cleaning chemicals may lead to micro-cracks or peeling.
Once the plating layer is compromised, the base material is directly exposed to water, significantly accelerating oxidation and resulting in rust spots.
Environmental Conditions (External Factor)
1.Water Quality: Hard water containing high levels of calcium and magnesium ions can leave mineral deposits on the spa jet surface, which in turn promotes localized corrosion. Chlorinated water is particularly aggressive, as chlorine can damage the protective plating film and accelerate oxidation.
2.Temperature & Humidity: Hot water environments increase the rate of chemical reactions, making the hot tub jet surfaces more prone to rust formation. Combined with prolonged high humidity, microscopic cracks in the surface become active corrosion points.
3.Usage Habits: In some cases, spa jets remain immersed for long periods or retain residual cleaning agents, leading to localized acidic or alkaline reactions that further speed up corrosion.
Launching the Optimization Project: Products Can Be Improved
The most direct improvement we could make was to upgrade the product itself. To address the material limitations of the earlier design, we initiated a material optimization project.
Testing revealed that spa jets with a plating thickness below 10 microns were prone to localized corrosion within just a few months in hard water or chlorinated environments.
By contrast, high-quality 304 stainless steel spa air jets showed almost no impact under the same conditions.
304 stainless steel, composed of approximately 18% chromium and 8% nickel, is well known for its corrosion resistance and oxidation resistance. Even under long-term exposure to water, cleaning agents, or hot water environments, it maintains a clean, polished surface. Salt spray testing confirmed this advantage: 304 stainless steel jets withstand over 500 hours of corrosion resistance in simulated environments, compared to only 50–100 hours for standard electroplated jets.
For this reason, the new generation of hot tub air jets has been fully upgraded to 304 stainless steel. With superior durability compared to plated components, they can resist the aggressive effects of chlorine and bromine sanitizers, ensuring a longer service life and a consistently glossy finish.
Since the environmental factors cannot be changed, we designed the product to adapt as much as possible.
Beyond standard performance testing, we conducted simulations of real-world usage, including high-temperature cycling, water with disinfectants, and prolonged soaking conditions.
The results showed that 304 stainless steel hot tub jets maintained stable performance and lasting shine, providing our clients with a far more reliable solution for their spas and wellness products.
Since the environmental factors cannot be changed, we designed the product to adapt as much as possible.
Beyond standard performance testing, we conducted simulations of real-world usage, including high-temperature cycling, water with disinfectants, and prolonged soaking conditions.
The results showed that 304 stainless steel hot tub jets maintained stable performance and lasting shine, providing our clients with a far more reliable solution for their spas and wellness products.
Similarly, we have upgraded our original plated plastic parts in large quantities by upgrading all their face caps to stainless steel. For example: hot tub drains, spa water jets, spa air jets, and so on.
Upgraded Professional Recommendations: Managing Environmental Impact
While environmental conditions cannot be changed on our side, they can be controlled by the end-user. To support our clients more effectively, we enhanced our professional recommendations:
1.Regular water testing to avoid excessive levels of chemicals.
2.Proper dosing of chlorine or bromine to ensure effective sanitation without accelerating corrosion.
3.Routine surface cleaning of the jets according to a set maintenance cycle.
By providing this guidance, we equip our clients with scientific and practical advice that they can share with their end-users. This not only reduces potential issues but also helps strengthen customer trust and satisfaction.
Tracking After-Sales Results: The Value of Secondary Feedback
After the 304 stainless steel hot tub air jets were introduced to the market, we closely monitored feedback from multiple clients. The results were overwhelmingly positive:
1.Enhanced end-user experience: The jet surfaces remained smooth and polished, with no rust spots even after extended use. This upgrade significantly improved the overall look and feel of the hot tub, leading to higher user satisfaction in daily operation.
2.Smoother client sales process: With the corrosion issue effectively resolved, our customers no longer had to worry about potential complaints or after-sales replacements. This not only reduced service costs and saved time but also made it easier to promote their hot tubs with confidence, resulting in more efficient sales conversions.
Extending Improvements to Related Products: Preventing Repeated Issues
Our optimization efforts were not limited to hot tub air jets alone. We applied the same material-upgrade approach to spa water jets, spa lights, and other components that remain submerged long-term. By extending the use of 304 stainless steel and other durable materials, we ensured that similar corrosion-related issues would not arise again, strengthening product reliability across the entire range.
Expanding Material Options for Hot Tub Accessories: Enhancing Clients Flexibility
| Dimension | ABS Chrome-Plated Spa Jet | 304 Stainless Steel Spa Jet |
| Base Material | ABS plastic, lightweight, non-rusting | Solid metal, robust and durable |
| Surface Finish | Chrome-plated, high surface gloss | Natural or polished finish, long-lasting shine |
| Corrosion Resistance | Adequate for standard water quality; attention needed in long-term or high-chlorine conditions | Stable in hot water and chlorinated/brominated environments |
Weight & Installation | Lightweight, easy to transport and install | Heavier, requires consideration for transport and installation |
Cost | Lower cost, suitable for budget-sensitive projects | Slightly higher cost, but long-term durability reduces after-sales concerns |
Application Scenarios | Entry-level configurations or cost-focused projects | Premium, commercial, or long-term stability-oriented projects |
Service Life | Meets standard usage cycles | Extended service life, less frequent maintenance |
While the product range has been upgraded, our aim is not to limit but to expand client choice. Different brands face diverse market demands across regions, each with unique priorities. Our role is to provide professional recommendations, helping clients weigh the balance between performance, cost, and durability—not to make the choice for them.
Final Words from Hydrorelax
Client and customer satisfaction has always been our core commitment.
Every piece of client feedback is a valuable driving force for product innovation and service improvement.
Through this air jet upgrade case, we not only resolved a practical issue but also strengthened industry insight and customer trust.
We warmly encourage more clients to actively share their market experiences, so we can work together to raise the standards of the hot tub industry. At Hydrorelax,we believe that high-quality products, professional guidance, and stable partnerships are the keys to helping our clients build stronger reputations and achieve long-term success in the market.
We are always ready to receive your inquiries and after-sales feedback!