Swimming pool enclosure manufacturing is a systematic process that involves a number of stages.

Normally, each stage determines the quality of the final product.

In this guide, I will take you through a step-by-step procedure that will make you understand every process involved.

It is a simple and easy to understand.

Whether you are a swimming pool enclosure reseller/distributor or consumer, this is an important document that you must read.

Here we go:

Step #1: Choose Right Materials

Any manufacturing process begins by choosing the right raw materials.

Without these raw materials, it will be useless to even plan for any swimming pool enclosure manufacturing process.

Remember, it is the raw materials that determine the cost of swimming pool enclosure.

choose the swimming pool enclosure

For a fact, companies that acquire raw materials at a cheaper price will sell their pool enclosures at a relatively affordable price.

Closely related to this, is the availability of labor.

Labor, will determine the cost of production.

Having said that, let’s focus on key materials we use to manufacture swimming pool enclosures.

Solid Polycarbonate Sheet

We use a solid polycarbonate sheet as the primary glazing material for all our pool enclosures.

Since 2001, Excelite Plastics Ltd. has been the leading manufacturer and supplier of solid polycarbonate sheets in North America and Europe.

Excelite polycarbonate sheet used forswimming pool enclosure manufacturing

Excelite solid polycarbonate sheet

At Excelite, we believe solid polycarbonate sheet is the only materials that can withstand harsh weather conditions.

Be it storm or wind.

It is for this reason that I will never recommend pool enclosures made from hollow polycarbonate sheets.

The main advantages of solid polycarbonate sheets include:

  • High impact resistance – virtually unbreakable
  • Filter harmful UV radiations.
  • Lightweight
  • Durable and reliable
  • Dimensionally stable
  • Easy to fabricate and customize
  • Available in a wide range of options

In short, before you begin any manufacturing process, ensure you have enough polycarbonate sheets.

For us, this is never a problem.

We have more than enough polycarbonate sheets at our disposal.

Extruded Aluminum Rods

Swimming pool enclosure requires a strong structure.

This makes extruded aluminum rods a perfect choice for this task.

Swimming pool enclosure manufacturing process (aluminum)

Quality aluminum rods

Generally, aluminum rods combine all the desirable physical and chemical properties.

That is,

  • Lightweight – making it easy to install and transport.
  • Corrosion resistance, thus, not affected by moisture
  • Ductile – making it easy to fabricate
  • Sustainable
  • Non-toxic
  • Easy to decorate and customize

These are the main reasons why we insist on constructing the entire structure of pool enclosures using aluminum rods.

In fact, the entire structure of pool enclosures is constructed from aluminum rods, including the track.

Enclosures for Outdoor Pools

Swimming pool enclosure aluminum track

Excelite Plastics Ltd. gets enough aluminum rods from Dolle (Suzhou).

One of leading supplier of aluminum and metal parts.

In short, swimming pool enclosure manufacturing raw materials is not a problem.

Furthermore, we obtain both polycarbonate sheet and aluminum rods at an affordable price.

This is the reason why our swimming pool enclosure is cheaper than other manufacturers in both America and Europe.

They are also of high quality.

Basically, these are the key swimming pool enclosure materials you need.

Next step, you need to design or have a drawing of the pool enclosure.

Step #2: Design and Technical Drawing

Designing is a critical stage in the pool enclosure manufacturing process.

Ideally, it involves putting all ideas together with an aim of having a complete product – swimming pool enclosure.

As a matter of fact, we a have a wide range of swimming pool enclosure designs to choose from.

The end user is at liberty to go for the standard designs or, customized options.

swimming pool enclosure manufacturing- different roofing designs

Swimming pool enclosure roofing designs

It is a requirement that the design process adheres to the building codes and standards.

This is the only way pool enclosure will be considered safe for use.

At this point, you need to work closely with our technical team.

It is the only way they will conceptualize all your ideas to come up with a technical drawing.

swimming pool enclosure manufacturing process technical drawing

A sample of a technical drawing for a swimming pool enclosure

For a fact, this is one of the most challenging process in swimming pool enclosure construction.

This because the technician must determine the following:

In most cases, you will have three level designs of a swimming pool enclosure:

Schematic drawing – a sketch of pool enclosure design and its basic components.

Design development – this is a detailed plan of the pool enclosure.

Construction plan – this is a more detailed drawing than the above.

It contains all the information about the swimming pool enclosure.

Normally, it comes with the pool enclosure installation manual.

By the end of this process, you should have a complete swimming pool design.

That is, a representation of what you will fabricate during the manufacturing process.

Step #3: Fabricate Each Component as Per the Above Design

The good news is you can fabricate polycarbonate sheets and aluminum rods to any shape of choice.

This will depend on the technical drawings you had in step #2 above.

Swimming pool enclosure manufacturing - a complete pool cover

A complete swimming pool enclosure

Remember, the amount of materials you need for the entire process will depend on the design of the swimming pool enclosure.

At this stage, you have to shape both the aluminum rod and polycarbonate sheet to conform to the desired shape.

As I had indicated earlier, the good thing is, both polycarbonate sheet and aluminum rods are flexible.

There are 3 main operations you need to consider at this stage.

These include:

Fabricating and Shaping Aluminum Rod

As you begin the swimming pool enclosure manufacturing process, you have to shape aluminum rods.

This may involve:

  • Cutting aluminum rods into smaller pieces based on the design requirements.
  • Drilling holes in the rods for fasteners.
  • Grinding sections
  • Milling

NOTE: Always take accurate measurements at every stage.

This is to avoid unnecessary wastage of aluminum metal.

It is a better way of reducing unnecessary costs.

Aluminum fabrication for swimming pool enclosure manufacturing

Process of aluminum rod fabrication

By the end of the process, you should be able to fabricate aluminum rods to form the desired shapes.

Fabricating Polycarbonate Sheets

Plastics fabrication involves a series of processes.

Depending of your swimming pool enclosure designs, you may consider the following:

  • CNC machining
  • Debarring
  • Polishing
  • Bending
  • Thermo-forming
  • Printing

In each of these processes, be sure to get the right tool and equipment for each task.

Normally, a complex and customized shapes may require sophisticated equipment, thus, high cost.

CNC machines for swimming pool enclosure manufacturing

                                     A CNC machine for fabricating polycarbonate sheet

In every process, you need to carry out all the necessary finishing operations.

That is, remove all unwanted sections and give the final surface an appealing look.

For example, cutting surface may leave sharp edges.

This can be dangerous as it may cut the technicians during the installation process.

This is not what we want.

All our products should be safe.

Conduct The Necessary Tests and Quality Validation

At this point, you should have all your swimming pool enclosure parts ready.

However, before you begin sorting out every component, testing and quality validation is an important process in swimming pool enclosure manufacturing process.

Excelite swimming pool enclosure

Remember, every component should comfort to the ASTM and ANSI manufacturing standards.

Otherwise, the swimming pool enclosure may not be sold in the U.S. and Europe.

Step #4: Sort Every Part as Per Specification

Sort out every component, of the swimming pool enclosure.

You should give clear descriptions of every component where necessary.

You need to label every section of the swimming pool enclosure.

That is, the labelling should be the same as that on the swimming pool installation manual.

This is to avoid confusions that may arise due to wrong labelling.

As a general rule, cross check the label and the enclosure part at least twice to be sure there is no error.

For Excelite swimming pool enclosures, this is never a problem.

Step #5: Pack The Product for Shipment

This is the last stage of swimming pool enclosure manufacturing process.

You need to pack every component in the shipping box.

swimming pool enclosure manufacturing process

A packed swimming pool enclosure ready for shipping

Don’t force anything in the box.

By forcing components in a small box, it will be nearly impossible to remove them.

As a result, some parts could get damaged in the process.

You should have all the necessary shock absorbers in place.

This will protect the swimming pool enclosure parts from high impact during the shipping process.

Also, remember to label the products appropriately.

More importantly, mark side that should face up plus all the necessary instructions.

Well, the process may seem simple, however, if you don’t have the right knowledge and expertise, it could be a nightmare.

End users don’t have to worry about this so much.

You will get all the Excelite swimming pool enclosures delivered to your door step.

Excelite has one of the most reliable and convenient shipping process.


Ideally, swimming pool enclosure manufacturing process involves these 5 basic steps.

These include material selection, technical drawing, fabrication, sorting parts and packing.

Of course, the process is not complete until the end user receives the final product.

That is, a complete swimming pool enclosure.