A hot air balloon – how is it made?

Due to the improvements in balloon manufacture it is now easier than ever to own your own hot air balloon. Computer Aided Design (CAD) and computer controlled machines has made ballooning affordable and not just reserved for commercial use.

A hot air balloon can come in a range of sizes and colours from simple standard balloon styles to complex shapes used for advertising purposes. To make a hot air balloon the initial design is modelled on a computer to check that it will fit neatly together and that the customer is happy with it.

Once the design has been approved it is then transferred to the big cutting tables; these are controlled by a computer to ensure that all the pieces will fit together. The balloons shape is cut out of a special non-rip material consisting of nylon for the main body of the balloon and a material called Hyperlast for the top of the balloon.

The newly cut out pieces are then stitched together using specially designed sewing machines; these use a unique stitch which is very strong and durable and the whole balloon is sent to be tested before final assembly.

Once the balloon passes its final inspection it is fitted with the all the fixings for the balloon basket or harness if it is a one man/hopper balloon and sent to the customer for its first flight.