Expedition Hardtop Caravan
Project Overview
Client | ZoneRV & One Composites
Manufacture Technique | Fiberglass Composite Layup
Zone RV, a leading manufacturer of premium caravans, wanted a new hardtop version of their already popular Expedition caravan. It needed to be functional and stylistically aligned with the original popup design.
Key Challenges
Utilise existing tooling and creating an exact replica and extension of the surface using client provided 3D Scan Data
Design a surface that looked aggressive but also complementary to the existing pop up design.
Use 3D scan data to replicate and extend surfaces, ensuring precise integration with the existing caravan.
Complete the project within an extremely tight timeline of just 5 days.
Our Process
To meet the tight timeline and complex requirements of this project, we followed a strategic and phased approach that combined creative design, technical expertise, and seamless collaboration with Zone RV.
1. Concept Development
We started the process by capturing the client's vision and ideas through hand sketches to explore several visual concepts. Using the initial sketches as a foundation, we developed multiple 3D model renders to present to the client.
2. Client Collaboration
Client Feedback: After presenting the 3D renderings, the client selected their preferred aesthetic concept. We then moved forward with refining the design.
3. Technical Implementation
Receiving 3D Scan Data: Zone RV provided us with 3D scan data of the existing Expedition caravan. This data was essential for ensuring that the new hardtop design would seamlessly integrate with the original platform.
Scan Data Cleanup & Assessment: We cleaned up the scan data to address any inconsistencies and assessed the deviations across both halves of the caravan, ensuring precision in the final design.
Coordination with Tooling Team: We worked closely with both Zone RV and the tooling team to determine the most cost-effective approach for generating add-on tooling. This collaboration ensured that the new hardtop design would be manufacturable without significant additional costs.
4. Design Finalization
Reverse Engineering: Using the cleaned scan data, we reverse-engineered the hardtop surfaces and integrated them with the original 3D model, ensuring the aesthetic remained consistent while optimizing for manufacturing feasibility.
Final 3D Concept: The final 3D concept was developed using real-world surface data, ensuring that the design was both accurate and feasible for production.
What we delivered
Optimised Tooling Surfaces: The final surface design was optimised for tooling, ensuring that the new hardtop version of the Expedition could be produced with efficiency and precision.
Brand-Reinforcing Aesthetic Design: The new design maintained the strong visual identity of the Expedition, with aggressive lines that conveyed the rugged, adventurous spirit of Zone RV’s brand, while offering a seamless extension of the original product.
Marketing-Ready Visuals: Even before manufacturing began, we provided Zone RV with high-quality, photorealistic renderings of the hardtop Expedition caravan. These visuals were ready for marketing and promotional materials, helping Zone RV present the new model to potential customers.
