Australia’s largest 3D printer is behind the making of the first Queensland-built Zone Expedition off-grid hybrid pop-top. This marks a significant milestone in the RV manufacturing industry as it introduces the concept of 3D printing into the production process.
The 22m x 5m 3D printer, said to be the largest in the southern hemisphere, played a crucial role in the creation of the Expedition, with the first prototype coming together thanks to 3D printed ‘plugs’.
Dave Biggar, Zone RV founder and CTO, outlined in a new video how the Queensland manufacturer built the initial prototype of the first fully moulded composite caravan in Zone RV’s 10-year history, entirely with the aid of a 3D printer.
The 3D printer, which arrived from overseas around late-2022, is now producing floors, roofs, and walls, along with many small parts for the Expedition, according to Caravan Camping Sales.
Biggar’s background prior to starting Zone was in composite manufacturing of catamarans and luxury boats.
He said the new Zone Expedition will be built in a similar manner to products from the aerospace, Formula One, and yacht racing industries, and brings the “weight and strength” benefits of top-grade “vacuum infusion” construction to the RV sector.
The significant investment in tooling and robotic assembly at the Zone factory will give the Queensland manufacturer a “competitive edge” in the premium off-road caravan segment. This segment includes other prominent Australian manufacturers like Kedron, Bushtracker, Mountain Trail, BruderX, Track Trailer, AOR, and Rhinomax.
“If this (composite moulded) process was cheap and easy you would see the whole market doing it,” Biggar said.
This statement highlights the innovative and pioneering nature of the project. The 3D printer is also being used to produce hulls for offshore speed boats, with Zone having established a separate factory at Coolum for their production.
The introduction of 3D printing into the RV manufacturing process is a game-changer. It not only speeds up the production process but also allows for more precise and intricate designs. This could potentially lead to more customized and personalized RVs in the future.
Featured image from Zone RV.
