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ULTIFLOAT: revolutionising swim training with bespoke foam

From concept to water-ready float – how we helped bring innovation to life

Background

ULTIFLOAT is a London-based start-up created by a Swim Coach with over 30 years’ experience. Designed to address the limitations of conventional swim floats, the ULTIFLOAT helps swimmers improve body alignment, balance, and technique from the very first stroke. Its unique two-grip design encourages correct posture in the water, making lessons easier for both coaches and swimmers.

When the ULTIFLOAT team approached us, they were looking for more than a manufacturer – they needed a foam conversion partner who could turn their concept into a safe, durable, and water-ready product. They wanted someone who understood the behaviour of foam and could help optimise the design from the very beginning.

Challenge

The concept was clear, but bringing it to life involved several challenges:

  • Choosing a foam with the right buoyancy and weight to suit swimmers of all ages and abilities
  • Making the float lightweight and easy to handle while also being durable enough for regular use
  • Creating a prototype that could be tested and refined before committing to full production
  • Incorporating precise design features, such as the heat-embossed grips, which required accuracy and careful attention during production

We knew that to succeed, we needed to combine our technical experience with a collaborative approach, guiding the ULTIFLOAT team through material choice, design optimisation, and production.

Solution

With over 50 years’ experience working exclusively with foam, we were confident we could help. We recommended a premium foam with the right density for buoyancy, comfort, and durability.

We created a prototype and worked closely with the founder through extensive testing to make sure every detail was perfect. The grips were heat embossed, a step that required precision to ensure consistency and usability. Using our CAD design capabilities and advanced production methods, we produced the initial 1,000 units to the exact specifications required.

The result is a high-quality, durable swim float that performs brilliantly in the water. Lightweight and easy to use, it allows swimmers to focus on technique from the very first lesson.

“Kewell Converters were extremely helpful – friendly, professional and supportive throughout the process.” Paul Dillon, ULTIFLOAT Founder

“It’s always exciting to work with a business bringing something new to market. Our job is to take an idea, listen carefully, and then use our experience to make sure the foam performs exactly as it needs to.” Nick Kewell, Managing Director, Kewell Converters

Looking ahead

Following the launch, ULTIFLOAT is now exploring new colours and designs. This project shows how we combine technical expertise with a collaborative approach, helping innovators take ambitious ideas and turn them into practical, exceptional products.

Got an idea that needs the right foam expertise to make it real?

Partner with Kewell Converters and turn your concept into a market-ready product. Contact us today.