Camper van interior made almost entirely from 3D printed parts
The prototype, made by Buckley Conversions, shed about 1,500 pounds compared with the outfitter's previous standard build
Buckley Conversions, a van outfitter run by Brandon Buckley, has built a prototype camper van interior using 3D scanning and large-format industrial 3D printing instead of the wood and aluminum construction typical of the segment.
The build was based on a Mercedes-Benz eSprinter with a 144-inch wheelbase and, according to Buckley, cut about 1,500 pounds from the vehicle compared with the company’s previous standard conversion.
Printing the interior
The team used a KUKA industrial robot, fitted with an extruder at its end effector, to print large-format components directly to the shape of the van’s interior. Buckley said the project drew on aerospace expertise, including engineers with SpaceX backgrounds, to cut weight and reduce reliance on manual measurement during assembly. Components were designed digitally around the vehicle’s structure from the outset, an approach Buckley said also simplifies customization and repeat production.
The couch, cabinetry and wall panels were printed in polypropylene, and wood was limited to the tambour faces of the overhead cabinets and a ceiling insert, while flat surfaces such as countertops used Richlite panels. Buckley said the company plans to replace the wood and Richlite components with composite panels on its next build.
Weight savings and systems
Buckley described the finished prototype as “the world’s first ever 3D printed luxury van”. Beyond the printed structure, the van carries a 10-kWh, 48-volt LiFePO4 battery, a 3,000-watt inverter and a 2,000-watt solar array, with the 170-inch wheelbase version able to take up to 2,500 watts of solar.
It also includes Rixen hydronic heated flooring and an 11,000-BTU, 48-volt air-conditioning system. Buckley said the weight reduction from 3D printing could improve range, acceleration, handling and braking on the electric platform.
