Inflatable Boat Fabrics, Explained
We build with three tube fabrics — German VALMEX 0.9 mm PVC, German VALMEX 1.2 mm Heavy-Duty Plus, and French ORCA 828 Hypalon (CSM). Here's exactly what each one is, how long it lasts, where it's used in our range and why Hypalon costs more.
At-a-glance comparison
| VALMEX 0.9 mm | VALMEX 1.2 mm Heavy-Duty Plus | ORCA 828 Hypalon (CSM) | |
|---|---|---|---|
| Base material | PVC (polyvinyl chloride) | Reinforced PVC, heavier weave | CSM synthetic rubber (Hypalon) |
| Origin | Mehler / Germany 🇩🇪 | Mehler / Germany 🇩🇪 | Pennel & Flipo / France 🇫🇷 |
| Weight | ~ 1,100 g/m² | ~ 1,450 g/m² | ~ 1,330 g/m² |
| Seam method | Heat / RF-welded | Heat / RF-welded (4-step) | Hand-glued, multi-coat |
| Lifespan (AU UV) | 7–9 years | 10–12 years | 15–20 years |
| UV / ozone | Good | Very good | Outstanding |
| Abrasion / rocks | Good | Excellent | Excellent |
| Field repair | PVC glue, quick | PVC glue, quick | 2-part Hypalon glue, slower |
| Cost vs PVC | Baseline | +15–20% | +35–55% |
| Boats in our range | AeroCat 330 / 360 / 380 | Aerowave Viper, Sovereign, WaveRunner | Viper, AeroCat & Monohulls — build-to-order |
What's actually inside the fabric
All three are composite textiles — a woven polyester core for strength, with protective coatings on each face. The differences are coating count, coating chemistry and weave density.
- PVC top coat — UV / colour
- Adhesion layer
- Polyester scrim (1100 dtex) — tensile core
- Adhesion layer
- PVC bottom coat
- PVC top coat (lacquered) — anti-UV + anti-fungal
- Adhesion layer
- Heavier polyester scrim (1670 dtex) — denser weave
- Adhesion layer
- PVC bottom coat (lacquered)
- Hypalon outer coat ×2 — UV / ozone barrier
- Neoprene tie coat
- Polyester scrim
- Neoprene tie coat
- Hypalon inner coat ×2 — air-tight
VALMEX 0.9 mm PVC
AeroCat 330 / 360 / 380The lighter, faster-to-pack-down option. Same German Mehler base as our 1.2 mm, but with a thinner coating and a 1100 dtex polyester scrim instead of 1670. That cuts ~30% of the tube weight, which matters when one person is car-topping a catamaran.
- Heat-welded seams — no glue ageing, no humidity issues during build.
- Best choice when total packed weight is the priority (rooftop / motorhome storage).
- Repair kit + PVC glue patches a puncture in under 10 minutes.
VALMEX 1.2 mm Heavy-Duty Plus
Our flagship fabricThis is what every Aerowave Viper, Sovereign and WaveRunner hull is made from. Thicker coating, denser 1670 dtex polyester scrim, and an extra lacquer pass on both faces for UV + anti-fungal protection. Stiffer tubes, more puncture resistance against oyster shell and rock, and a noticeably longer service life.
- 4-step thermo-welded seams — internal weld, external weld, reinforced overlap, capped finish.
- Holds higher pressure without "creep" → a stiffer, faster boat on plane.
- Direct competitor comparison: TrueKit Discovery 4.0 ships with 0.9 mm. Our Viper 400 ships with this 1.2 mm.
ORCA 828 Hypalon (CSM)
Build-to-order on Viper, AeroCat & MonohullsHypalon is the chemistry of choice for commercial RIBs, naval tenders and tropical charter fleets. It is a synthetic rubber (chlorosulphonated polyethylene) made by Pennel & Flipo in France under the ORCA brand. Where PVC slowly hardens and chalks under tropical UV, Hypalon stays flexible for 15–20 years.
Why it costs more
- Raw material: ORCA 828 is 2–3× the per-metre cost of VALMEX PVC.
- No heat-welding. Every seam is hand-glued with 2-part polyurethane adhesive, rolled, cured, then over-taped — a Viper-sized hull takes 3–5 days of skilled labour vs ~1 day for PVC.
- Controlled humidity build room. Hypalon glue is humidity-sensitive, so factories run dehumidified booths during lay-up.
- Smaller global supply. Only a handful of mills produce CSM at marine grade.
Net effect: the same boat ordered in Hypalon is typically +35–55% over the VALMEX price, depending on size.
When Hypalon is worth it
- Permanent tropical mooring (NT, far-north QLD, the Kimberley).
- Boat lives on a davit / fly-bridge in constant UV — no tube cover.
- Commercial / hire-fleet use with daily abuse and unknown operators.
- Fuel and oil spillage exposure (Hypalon shrugs off both better than PVC).
For 90% of recreational owners storing the boat deflated, VALMEX 1.2 mm Heavy-Duty Plus is the better value choice.
Which boat comes in which fabric?
AeroCat 330 / 360 / 380
VALMEX 0.9 mm standard. Hypalon available to order (+35–55%, ~8 week lead time).
View AeroCats →Aerowave Viper & Sovereign
VALMEX 1.2 mm Heavy-Duty Plus standard. Hypalon available to order (+35–55%).
View Vipers →Monohull tenders
VALMEX 1.2 mm standard. Hypalon available to order — typically chosen for permanent davit-mounted yacht tenders.
View Monohulls →Not sure which fabric is right for you?
Tell us where the boat will live (garage, davit, tropical mooring), how often you'll use it and your engine — we'll recommend the fabric and warranty that actually fits, with a fixed quote.