How is a hot air balloon made?

Hot air ballooning has become very popular over the past three decades, and is now not only reserved for commercial use, but are accessible to hobbyists and companies looking for unique advertising platforms too.

This new found popularity is not just down to the truly remarkable experience of floating high above the ground, it is also due to the price dramatically falling, as the introduction of new technologies such as computer aided design and new materials cut manufacturing costs.

There are various sizes and shapes of hot air balloon from one man and hopper balloons, to commercial passenger balloons and even specially shaped balloons for advertising. The process of making a hot air balloon starts with the initial design.

The design is first created on a computer with special software, printed out and sent to the customer for approval. Once approved, the design is transferred to the computer controlled cutting table, where the design is cut out of special non-rip material.

The cut-out design is then sewn together using specially designed sewing machines that use unique stitches, which provide strength and durability as well as stability to the structure. The balloon or envelope as it is known in the business is then sent for final assembly, where the envelope is rigorously tested.

Once the balloon envelope has passed all of the safety and strength tests, it is sent to the customer and ready to take its maiden flight.