A Lancashire manufacturer of bespoke wooden hot tubs which have attracted celebrity customers from the worlds of film and television is combining traditional craftsmanship with digital technology to drive its next phase of growth.
Preston-based Rustic Tubs has built a reputation for handcrafted wooden hot tubs and plunge pools, with its high-end products installed at homes and luxury hospitality destinations across the UK and Europe, including Portugal, Monaco and Switzerland.
Now, with support from Made Smarter North West, the specialist manufacturer has invested in 3D printing and design software to bring more product development in-house. The technology will enable Rustic Tubs to design, prototype and manufacture bespoke components, reducing reliance on oversized off-the-shelf parts while creating one new role and upskilling two existing employees.
Made Smarter's support has given us the opportunity to explore 3D printing and digital design tools that can help streamline product development and improve the way we manufacture.
The project has huge potential to strengthen the business and create opportunities we simply couldn't have explored before.
Andy Walsh, Founder of Rustic Tubs
Rustic Tubs is the brainchild of former civil engineer Andy Walsh, who began experimenting with wooden hot tubs almost 20 years ago after experiencing a homemade version during a trip to Norway.
Today, the business produces around 50 bespoke wooden hot tubs, plunge pools and Japanese baths each year from sustainably sourced Western Red Cedar for customers across the UK and Europe.
While every tub is bespoke, Rustic Tubs relied on commercially-available filtration systems designed for large swimming pools, requiring time-consuming modifications and handmade mounting brackets that added production time, installation costs and material waste.
Andy was encouraged to explore digital technology after seeing neighbouring manufacturers on the Whitestake industrial estate successfully adopt technology with support from Made Smarter.
"Seeing my neighbours thrive gave me the confidence to take the plunge with Made Smarter," he said. "There's probably more people around here who could benefit, it's just about spreading the word."
Following a Digital Transformation Workshop with Made Smarter, Rustic Tubs identified digital design and additive manufacturing as a practical solution to its production challenges.
Supported by a £4,000 grant, the business invested £8,000 in Autodesk Fusion 360 design software and a Creality K2 Plus Combo 3D printer, giving it the capability to design, prototype and manufacture bespoke components in-house.
The technology enables Rustic Tubs to produce compact filter housings, brackets and fixtures specifically for its products, rather than buying oversized standard components and modifying them manually for each installation.
It also gives the business greater freedom to experiment. Components can be designed digitally, printed, tested and refined quickly, allowing Andy to develop solutions when suitable off-the-shelf products do not exist.
The project is also building digital capability within the business, with two employees being trained in CAD design and 3D printing workflows to support future product development.
The investment is expected to reduce external spending on filter housings and brackets by at least 30 per cent, cut installation preparation time by 25 per cent and deliver a return on investment in less than six months.
Early use is already delivering savings, with seating brackets previously bought from suppliers now being 3D printed in-house.
"The printer hasn't stopped printing since the day I got it," Andy said. "It's been churning out seating brackets every day and we're saving about 80 per cent per bracket."
The new capability will reduce reliance on suppliers and enable a faster response to bespoke requirements. By cutting transport and material waste and replacing oversized components, the project is also expected to deliver carbon savings of around 3.7 tonnes of CO₂ each year.
Rustic Tubs also plans to build a digital library of reusable designs that can be adapted for future projects.
Andy is already using the technology to explore alternative water jet designs where existing products do not meet the business's needs.
Rustic Tubs sees the investment as the first step in a broader digital transformation.
Over the next three years, the business plans to expand its use of CAD, CNC machining and digital prototyping, while exploring sensors and data to monitor product performance.
It also aims to develop an online portal where customers can configure bespoke hot tubs, receive instant quotations and track orders, while using its new design capabilities to develop products and accessories and expand into premium wellness, hospitality and luxury accommodation markets.
