For over half a century, ZODIAC has been the leader in the high-tech application of flexible composite fabrics used in everything from dirigibles to swimming pools, pontoons to parachutes. But it is out leadership in inflatable boat technology that has made ZODIAC the worldwide standard of quality. The simple fact is that ZODIAC pioneered just about every technological breakthrough in the history of inflatables. Still a leading maker of hypalon inflatables, we've gone on to break new ground in the development of co-polymer coated fabrics which can be thermo-bonded to insure airtight seams. ZODIAC technology continues to be driven by the demand for ever improved performance under a wide range of conditions at sea. Our customers have every right to expect more from a ZODIAC - more airtightness, more rigidity, more rugged endurance under all the punishment sea and sun and weather can dish out.

The latest ZODIAC innovation is a technological marriage of an improved fabric, a superior coating and a remarkable thermo-bonding process that delivers the most airtight rigid construction ever devised. That material makes our new inflatables easier than ever to repair and maintain. And, as an extra bonus, it incorporates vastly improved resistance to degradation from UV light. Zodiac ensures its reputation for unsurpassed quality with a policy no other manufacturer has dared to impose: no ZODIAC improvement is introduced to our customers until it passes a muster in a painstaking laboratory qualification process followed by a 2-year field testing program. For more details on the latest ZODIAC breakthrough, just keep reading.

ZODIAC turned to space-age government research, using a polyester material which is woven into a rugged support fabric. We wanted a fabric that was rigid enough to prevent the stretching that could lead to permanent deformity under either static or dynamic load conditions. At the same time, we had to build into it the ability to resist tearing, ruptures, warping, elongation, and abrasion.

Stretch resistance/memory to prevent excessive or permanent deformity under static and dynamic load conditions.

Must resist, low down, and stop tears. These characteristics assure longer life and durability in the substrate fabric.

Because no woven fabric can exclude air or water, it must be coated. Our co-polymer coating is the best ever developed for inflatables. This unique coating is applied in a hot liquid state. It is then smoothed onto the fabric and fed between rollers which firmly seal the openings in the weave. This process is called "calendering".

Many manufacturers economize by using only a single coating of recycled material on either side of their fabric. But that can leave the fabric vulnerable to coating imperfections such as dust particles or air bubbles which would reduce air and water tightness.

The finished ZODIAC fabric, however, is protected by multiple coatings that build up to the required thickness. As a result, any imperfections in one layer are covered by an additional layer of coating. This not only assures a superior seal against air and water, but enhances the fabric's resistance to environmental wear and tear.

The result is a co-polymer composite fabric fortified both chemically and mechanically against a wide range of natural and man-made damage.

Thermo-Bonded Seams	A crucial manufacturing step is the point at which our coated co-polymer fabric is ready to be precision cut and assembled by computer robotics into a finished inflatable. ZODIAC technology has pioneered an improved method of insuring that the construction seams are sealed tightly and permanently against air and water. It's called "Thermo-Bonding". Two sealing strips are thermally bonded to the butted hull seams in a continuous electrochemical process. A highly impermeable air seal is formed when the narrow inner strip literally melts into the hull material. The wider exterior strip functions as an overlapping structural connection while also effectively sealing out water.
Computerized Accuracy	The procedure described above is controlled by space-age electronic welding equipment which eliminates human error. As a matter of fact, a full 95% of our entire manufacturing process is computerized to assure maximum levels of accuracy, dependability and repeatability in meeting our strict design specifications.
Welded Transom	Given the size, weight and power of today's outboards, the transom which supports them must be able to stand up to enormous vibration and stress. Many ZODIACs use a computerized high-frequency welding technique that firmly attaches eight studs to the tube collars. The result is a degree of structural rigidity that reliably absorbs the stresses exerted by modern outboards.
Semi-Recessed Value	A dependable valve is a crucial element in preserving airtightness. All ZODIAC inflatables are fitted with rugged semi-recessed valves of resin reinforced with fiberglass. The valve cap with its airtight O ring protects against leakage, while a special collar holds the valve firmly in place to maintain airtightness between it and the fabric. The semi-recessed design allows for more rapid inflation and deflation. While airflow is instantly adjustable at the touch of a finger, a safety valve guards against accidental deflation. Our valve thread bears out the old adage that "perfection is in the details". We've replace the traditional thread design with a unique rectangular profile that provides three flat points of contact to lock the valve securely in place.

 

ZODIAC Design

Designed for High Performance

 

If ZODIAC manufacturing focuses on the key characteristics of airtightness and rigidity, ZODIAC design works to enhance the performance improvements these characteristics make possible.

 

HPP Air-Floor

Our unique HPP (High Pressure Performance) Air-Floor is a ZODIAC breakthrough that delivers the strength and rigidity of insertable plywood or aluminum floors while doing away with the hassle of assembling and disassembling sections. This is because the HPP floor is inflatable.

Made of durable co-polymer with multiple under layers of fabric, it is braced with thousands of polyester cross stitches. The payoff is a rigidity equal to that of a 3/8 inch marine plywood floor at only a fraction of the weight. It also offers the speed and convenience of deflating and packing the inflatable away without having to deal with a single removable part.

 

 

High Performance Hull

One of the most significant of ZODIAC's many technological firsts, this radical speed tube design get the ZODIAC "up on a plane" more quickly and holds it there. A skirt connects the speed tubes, giving the boat exceptional lift that allows it to skim the waves like a hydrofoil. This not only addresses a smoother, more fuel-efficient ride, but a faster one as well. For example, our patented Futura Junior, when mounted with a 10 HP outboard, can carry one person at speeds of up to 30 mph.

 

Tube Diameter Options

The greater the tube diameter, the more rigid the hull. How much rigidity is appropriate? That depends on the power, size and carrying capacity required by the user. Because our 28 ZODIAC models were developed for specific applications, something as crucial as tube diameters are not designed to a "one-size-fits-all" concept.

For example, our Cadet S series of yacht tenders, averaging only 8 ft. in length, is built to carry no more than three or four people and load of under 1,000 lbs. By contrast, the ZODIAC Grand Raid line of heavy-duty inflatables must be able to seat up to ten people and handle payloads of almost 3,000 lbs. Which is shy ZODIAC alone offers twelve different tube diameters, as opposed to only three by our leading competitors.

 

Return to Inflatables