The three layer superlinear hull used on our Discovery® canoes is produced by an exclusive, rotational molding process developed here at Old Town by the innovative Lew Gilman. Introduced in 1983 after years of research and development, the Discovery hull is a scientifically-designed structural sandwich that includes a layer of closed cell foam surrounded by layers of high-density polyethylene. This combination, and the unique process by which it is accomplished, are the principle reasons for the material's strength. The material also ensures buoyancy; filled with water, the canoe will remain afloat.

Each Discovery hull starts out as measured amounts of tiny plastic granules, introduced in sequence into a mold for lamination. The mold is held by a mechanical arm and conveyor assembly, which gently rocks and rotates it in a series of pre-set directions, then transports it to a large, high-temperature oven. Finally, the hull is removed from the mold and allowed to cool before finishing out with seats, rails and decking.

Among the critical factors in the process are the frequency and duration of heating and cooling cycles, proper angle and speed of rotation, and the quality of the polyethylene and of the mold itself.

This process accounts for one of the reasons a Discovery's dents pop out so easily. The natural tendency of Three Layer Superlinear is to return to the original shape in which it was molded.

Gilman puts it in more scientific terms: "Three Layer Superlinear is a composition that features an intertwined chemical bond that greatly out-performs traditional linear polyethylenes. The material's unique molecular structure also results in high ultra-violet light resistance and environmental stress crack resistance."