Expedition Hardtop Caravan
The Brief
Client | ZoneRV & One Composites
Manufacture Technique | Fiberglass Composite Layup
Photos | Courtesy of Devote Digital & ZoneRV
Zone RV, a leading manufacturer of premium caravans, tasked us with creating a 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 began by capturing the vision through quick hand sketches, then moved into multiple 3D model renders to explore direction and proportion at speed. This set a clear aesthetic path while keeping momentum high.
We presented the render set, gathered focused feedback, and the team selected a preferred look. With alignment in place, we refined the chosen direction and prepared for technical integration.
2. Technical Implementation
Zone RV supplied 3D scan data of the existing Expedition. We cleaned the scan, assessed deviations across both halves, and validated interfaces so the hardtop would integrate cleanly with the current platform. In parallel, we coordinated with the tooling team to map the most cost-effective approach for any add-on tooling.
3. Design Finalization
Using the cleaned scan as ground truth, we reverse-engineered and extended surfaces to deliver an accurate, manufacturable hardtop. The production-grade 3D model doubled for photoreal visuals, which made stakeholder sign-off fast and unambiguous.
From Left to Right
1. Original Pop Top Body 2. 3D Scan of existing Tooling 3. Deviation Analysis of Tools 4. Surface Extraction from 3D Scans 5. New Hardtop Surface 6. Finished Integration
What we delivered
Tooling-ready surfaces
Optimised hardtop surfacing that integrates with existing tools and reduces reworkOn-brand aesthetic
Aggressive, cohesive styling that complements the original Expedition design languageMarketing-ready renders
High-quality visuals produced from the production geometry for early marketing and stakeholder alignment
