Welcome to SWELL Manufacturing. Below you will find proprietary information on Swell Manufacturing's management team, engineering capability and showcase of Swell MFG's wave park technology. Information found on this page is not to be copied or shared without written consent of Swell Mfg. Thank you for keeping our information private and secure. We look forward to working with you as we bring Swell Mfg waves to market.
Management Team
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Matthew Gunn, Owner/Founder
Well trained business professional with an entrepreneurial spirit and 15 + years' experience in hospitality and real estate, managing Fortune 100 clients and 30+ million dollar accounts. Matthew, raised in Ventura County Los Angeles, grew up close to the ocean and experienced the growth of the action sports industry first hand. While a student of business, his love for the ocean, sports and continual entrepreneurial spirit continue to drive Matthew's focus. After multiple years of R&D, founding Swell Manufacturing. His experience and years of in-depth study of oceanography, bathymetry and surf systems have refined Matthew's skills in reef shaping and wave hydrodynamics. Coupled with heavy hands on R&D digging reef after reef himself to find perfect depths, shape and angles to verify theory and bring Swell Mfg into the future. Matthew resides in Phoenix Arizona with his wife and 3 boys. |
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Accomplishments:
Developed successful start up hospitality software company
Managed Olympic venue events with Utah Winter Games 2002
Licensed Arizona real estate professional
Developed successful start up hospitality software company
Managed Olympic venue events with Utah Winter Games 2002
Licensed Arizona real estate professional
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John Bushey, Chief Engineer
John is a highly experienced mechanical engineer with an extensive track record of solving unique and difficult problems in motion system design, high performance hydraulic systems, mechanical design and design for production. John is responsible for Swell Mfg's overall wave engineering design and equipment as well as consultation in hydrodynamics and wave mapping. John has designed and developed many machines in his extensive career with MTS including multiple wave generator systems of various sizes pushing swells from a matter of inches to 8 feet in height. Wave generators designed to measure critical performance in study of erosion through hurricane and tsunami simulation to pushing 8 foot swells under extreme stress for the US Military. John resides in Minneapolis Minnesota with his wife Mary and their two dogs (really big dogs!). |
OSU tsunami basin mechanical area
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Engineering Accomplishments:
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O.H. Hinsdale Wave Research Laboratory: System engineer and designer for two wave generators at the O.H. Hinsdale Wave Research Laboratory, Oregon State University.
Tsunami Wave Basin (Top video) - segmented multi-channel wave maker utilized for study of coastal erosion and tsunami simulation. For an ideal of the scale of this wave basin, the steel plates pictured are roughly 8' tall. John in the picture above is standing underneath and behind the wave plates. Wave Flume (second video) - The largest wave flume in North America, generating waves using a unique long stroke, high velocity hydraulic actuator. The design also used to study tsunami simulation and wave action against larger structures affected by the ocean. |
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Wave Generator - US Military
Wave system built for military training. Swell Mfg's current surf generator is designed with this Military application as it's base. This application designed for military training in high surf advisory shore attack/retreat situations. The basin is 20' deep with an aggressive slope to the shore providing for heavy shore break waves. The generator has been operating since 2006 and continues to operate today. The lake remains private due to its proximity within a military training base.
Wave system built for military training. Swell Mfg's current surf generator is designed with this Military application as it's base. This application designed for military training in high surf advisory shore attack/retreat situations. The basin is 20' deep with an aggressive slope to the shore providing for heavy shore break waves. The generator has been operating since 2006 and continues to operate today. The lake remains private due to its proximity within a military training base.
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The Concept
Swell Mfg's wave system provides a unique attraction for water recreation. Complementing sporting facilities, entertainment centers, hotel, retail, mixed use, residential an any other leisure centers as an added attraction. Swell Mfg offers a combination of beach lifestyle environment with world class waves desired by the most demanding surfers while offering fun and exiting wave riding opportunities to those experiencing for the first time. Swell Mfg's achievement in wave production is remarkable teeing up the most productive and high quality artificial waves in the market. Enabling high quality at sustainable cost. Designed with an open concept the technology reduces build out costs, provides for less energy consumption and holds a long term track record of efficient operation. Pushing smooth wave crests across the lagoon before turning them into beautifully breaking waves.
Swell Mfg's wave system is unlike any other on the market. Deployed as a stand alone wave generator into existing wave pools, surf pools or a entirely new attraction where world class surfing is desired. Providing an affordable attraction with reliable unencumbered wave generation for years to come. Swell Mfg's wave generator provides multiple wave patterns, wave heights up to 6 feet and at adjustable angles providing customized experiences at the push of a button. With the ability to be built as an open or closed concept, Swell Mfg is a wave generator unlike any ever seen. Providing visible wave generation for the enjoyment of those participating or spectating. Watching the marvel waves created before there eyes.
The Attraction
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Surf Specific
Swell Mfg's wave generation system offers slow rolling waves to fast, high performance surfing and combinations in between. Through segmented wave making technology, high quality surf waves are produced through a computerized playlist producing an endless combination of waves. Waves pushed in all directions and types, simulating world class surf. Specifically designed reefs by Swell Mfg provide for an entire wave attraction that provides world class point breaks, peeling along reefs. Churning out barrel after barrel with ripable wave sections and endless fun. Each wave adjustable to desired results from long drawn out swell lines to shorter converging powerful barrels. |
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Wave Play / Surf Combination
Turn an existing swimming/bobbing wave pool into an all new, updated, refreshing attraction. Providing smaller waves at low energy for swimming and wading with the opportunity to turn up the volume. Surfing quality, larger waves of the finest beach break found along the cost. Slow the wave down to enjoy a packed house of swimmers or pick up the pace with high paying surfers/body boarders looking for an all new experience. Where common blower or paddle wave making equipment is limited, Swell Mfg provides for all types of needs. |
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Generator Design
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John Bushey, Swell Mfg's chief engineer has built numerous wave generators over a long, successful career. The above military wave generator is what Swell Mfg's current generator is modeled after. Comparable in method and construction, improvements were made to the military generator to reduce infrastructure and cost while improving performance. This improved generator is the existing generator of Swell Mfg today. Maintaining reliability, strength and high operating output under reduced consumption and reduced initial capital requirements. Enabling Swell Mfg to utilize stored energy under less stress and lower power cost.
Key Features
- Visible, open concept wave generation - No mechanical parts within the water - Low maintenance - Modular design with individual plunger controls - OEM power equipment and controls - Built in contingency planning mechanisms - Built in safety controls |
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Surf Lake Design
For new projects, multiple design layouts may be utilized depending on land available and budget. The Swell Mfg modeled lake provides an ideal design of a trapezoidal shape. The actual shape of the lake providing for many functional features that also including maximizing viewing opportunity. Additional lagoon areas may be added to the design which complement for the size of project and desired ride length. The shown design is driven from an exact replica of Swell Mfg's physical modeling through point mapping of the 1:10 scale model.
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Design Functions
- 4 main break areas: 8 riders per swell - Evenly split wave opportunities (advanced and beginner) - Maintain tight footprint of 2 acre lake - Quality ride length with high throughput - Minimizing water management - 2.2M gallons - Current damping and mitigation system - Simple outline and ease of excavation |
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Scale Modeling
Located in Phoenix (Queen Creek) Arizona, Swell Mfg's complete 1:10 scale model produces wave heights of 7" to 8" waves running a length of 18 feet with multiple waves breaks designed into the model lake. Providing 3 different wave types through reefs and channels fitting needs of beginner, intermediate and advanced surfers.
"A" Frame center peak with hollow left and right barrel leading to peeling, ripable walls (2 riders at a time)
"Jetty" wave running down each side, One breaking left, the other breaking right (2 riders at a time)
Inside beginner section smaller waves, whitewater take off with wave reformation (4 riders at a time)
"Jetty" wave running down each side, One breaking left, the other breaking right (2 riders at a time)
Inside beginner section smaller waves, whitewater take off with wave reformation (4 riders at a time)
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How does the model work?
Wave Generator: The scale model is generated by 6 plungers, connected to steel arms and torque tube held by pillow bearings secured to an angled platform. Driven by track and wheel system. Each able to be actuated individual to enhance wave shape and form. Power: Driven by a pneumatic actuator for the 1:10 size modeling. Full scale facilities will be driven by hydraulics due to increased efficiency and accuracy during the wave generation process. Reefs: Various reefs are shaped into the contours of the lake providing necessary benefits of increased wave break areas, required dead zones, current mitigation and separation/spacing of surfing patrons. Lake Design: Designed with an overall trapezoidal shape offering both outside 'expert' wave riding opportunities over reef with beginner areas offered on the inside. |
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Wave Frequency
Swell Mfg produces high throughput at affordable cost. This is accomplished through highly efficient wave generation which takes advantage of refraction. This is coupled with a hydraulic energy storage system creating even power pull, avoiding high increases in power. Waves can be generated in as little as every 4-6 seconds depending on the power storage system identified. Throughput in completed modeling produced 20 - 30 second intervals. Taking advantage of reefs and more waves ridden per swell through multiple breaks vs increase in costly power consumption. While Swell Mfg's wave generation can operate continually (4 second wave cycle) given proper power is applied, generating swells every 20 - 30 seconds provides for optimal patron throughput, safety management and lowest overall cost and energy use. 3 swells per minute provide 96 patrons surfing per hour with 15 waves per rider per hour...or a wave every 4 minutes.
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At 2 Swells Per Minute / Every 30 seconds:
120 swells generated per hour 480 ride opportunities (intermediate/advanced) 480 ride opportunities (beginner) 960 total ride opportunities per hour 60 patrons per hour - 16+ waves per hour, per person |
At 3 Swells Per Minute / Every 20 seconds:
180 swells generated per hour 720 ride opportunities (intermediate/advanced) 720 ride opportunities (beginner) 1440 total ride opportunities per hour 96 patrons per hour - 24 waves per hour, per person |
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AT 60 SURFERS PER HOUR: 480 sessions day / 3,360 week / 13,440 month / 161,280 year
REVENUE POTENTIAL: $9,676,800 ANNUALLY...Based on 8 hour day at current market rate: $60 per hour |
Wave Types
Depending on the type of installment, Swell Mfg can fit into flat bottom (non contoured pool) as a beach break or Swell Mfg built as a new attraction combines both reefs and swell angle to provide a best experience. Swell Mfg's generator can adjust the swell angle with the click of a button, forcing waves to interact with the floor and reef at various points. Producing long drawn out lines to punchy barrels depending on the audience. With adjustable peel angles wave types are infinite and can be changed like shifting songs on your music playlist. Reefs also produce added dead zones in the water without breaking waves. Inviting patrons to ride their wave and then paddle back out through a channel. This channel provides multiple benefits, but one of the greatest benefits is controlling and organizing the lineup.
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"A" Frame Center Peak Advanced wave offering aggressive take off zone Barrels and ripable high performance wall 
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Jetty Wave Left and right hand breaks peeling along the side reef hugging deep water channel to the outisde. 
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Inside Section Whitewater take off wave with reform sections. Suitable for beginners to those beginning to turn 
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Power Consumption
Power consumption is driven over a continual power draw vs high up and down power use which accompany higher rates. Swell Mfg's surf generator utilizes a power storage system enabling consumption at lower power rates. Completely avoiding spikes in usage during each wave generation. This is smiled upon by an owners pocket book with lower cost and the power company as Swell Mfg requires less draw on power grids. Just like a rechargeable battery which is charged and then used at will.
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Keys of Power Consumption:
- Operating power: 299 kWatt / 410 HP (3 swells min) - Generator Hourly Operating Cost: $48 per hour - Continual draw vs high/low peak draw Average $0.16 kW |
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Water Filtration
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Swell Mfg has done the research and acquired best in class support to provide for required filtration consultation creating inviting crystal clear water. Involving NSF certified filtration through Advanced Oxidation Processes (AOP) which utilizes ozone in the presence of catalysts and/or electro-catalysts to form several powerful mixed oxidants such as hydroxyl radicals, hydrogen peroxide, and atomic oxygen. In other words, less chemicals, cleaner, bright blue water. These functions work together to mineralize organic pollutants converting them to carbon dioxide and water.
Swell Mfg filtration is completed with adding a combination of sonic algae control to safety and effectively manage water with less chemicals. To comply with county chlorine/ph balance regulations an on site chlorine generator proving better, safer water tops off the filtration system. Eliminating the need for traditional liquid chlorine. |
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Lake Lining
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Lake lining is a proven cost effective strategy for holding water in lakes of large size. For a surf lake it reduces cost and increases flexibility. Liners are also proven in various surf applications for maintaining a non porous lake bottom which will not break down due to the power of breaking waves and flowing water. While an effective form of cost efficient water retention, standard lake liners are also not thick enough alone to account for patron usage. Cuts from surfboard fins, nose pokes and feet are a problem. Our 3 layer lake lining system is comprised of geotextile and geomembrane liner with fiber fused gypsum based epoxy material. A bulletproof 3 tiered system which increases overall thickness and adds considerable strength and longevity to the lake lining.
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The base product of this material is free of Volatile Organic Compounds (VOC), BPA-free and rated for use in potable water (NSF-61/AWWA D102). When it is time to service the material, the material can be re-applied to itself for the life of the coating.