Making Waves: First-Ever HDPE Canal Boat Launched

Author: Mark Hobbs, Commercial Director, Welwyn Tool Group Ltd

From Concept to Canal

When Adrift Boats approached Formation Plastics with the ambitious idea of constructing a full-sized canal boat entirely from high-density polyethylene (HDPE), it was clear: this would be no ordinary project. As long-time experts in plastic fabrication, Formation Plastics saw the potential—and the challenge. 

The goal? Build a durable, sustainable vessel using only HDPE, a first-of-its-kind innovation in boatbuilding. To bring this vision to life, the team needed not only experience but the right equipment and support. That’s where Leister came in.

Welding Innovation into Every Inch

Formation Plastics had already been relying on Leister’s trusted tools such as the TRIAC ST, TRIAC AT, and WELDPLAST S4 for previous projects. But this build required even more power, flexibility, second and precision. With Leister’s support, they expanded their welding toolkit to include the WELDPLAST S2, FUSION 1, and FUSION 2.

Each tool brought unique strengths to the table: 

• FUSION 1 handled tight and intricate areas. 
• FUSION 2 ensured high-strength welds on larger seams. 
• WELDPLAST S2 delivered consistent, heavy-duty extrusion performance.

Custom welding shoes were also used to adapt to different weld types and finishes—tailored precision from bow to stern. 

Reliable Support at Every Stage

As the build progressed, the collaboration with Leister proved essential. Technical support and rapid repair services ensured minimal downtime, helping Formation Plastics stay on schedule. The partnership demonstrated how innovation can thrive when equipment and expertise go hand in hand. The result is more than just a canal boat. It’s a symbol of what’s possible when creative vision, advanced materials, and the right tools converge.

Sustainability That Floats

Lightweight, robust, and 100% recyclable, the HDPE canal boat is redefining marine construction. In a world where sustainability and durability are more important than ever, Formation Plastics and Adrift Boats have set a new course for the industry—with Leister by their side.

Ready to Weld Your Next Big Idea?

Whether you're building boats, tanks, or trailblazing new applications with thermoplastics—Leister’s welding tools and expert support are here to help you innovate with confidence.