Caracol AM unveils THE CAB, a 3D printed RV made from recycled polymer
On display at Formnext, the latest project demonstrates faster production, reduced waste, and modular design for sustainable mobile living
Caracol AM, in partnership with LG Project Management, has developed what it describes as the first fully functional, 3D printed recreational vehicle (RV) produced in a single piece using recycled materials. The project, known as THE CAB, leverages Caracol’s robotic large-format additive manufacturing (LFAM) platform, Heron AM, to fabricate a monocoque mobile living module without the use of traditional molds or multi-part assemblies.
The RV was printed in 92 hours using a recycled PET-based polymer reinforced with glass fiber and treated for UV resistance. The resulting structure weighs 660 kilograms and measures 4.3 by 2.1 by 2.1 meters. According to Caracol, this additive process reduced material waste by 60% compared to conventional fiberglass lamination methods and cut production time from roughly three months to one week.
On Tuesday, November 18, at 16:00, at Caracol’s booth C101 in Hall 12.1, THE CAB’s founder, Gregorio Delcò, will share insights about THE CAB project and how additive manufacturing is transforming the mobility sector during the event “Disrupting Transportation: Redefining Sea, Rail and Road”.
One piece of sustainable manufacturing
Caracol’s Heron AM system enabled engineers to embed channels and cavities directly into the printed RV shell, streamlining installation of electrical, plumbing, and heating systems. This digital-first approach is designed to minimize potential failure points while enabling rapid customization for various use cases, including campers, mobile offices, tiny homes, or floating living units.
The RV’s structural integrity and vibration resistance are credited to the one-piece design, which eliminates joints and adhesives. The companies say the project illustrates how LFAM can support industrial-grade applications while meeting the mechanical and thermal performance demands of mobile environments.
Going in virtuous circles
THE CAB represents a collaboration between Swiss-based LG Project Management, which focuses on sustainable transportation projects, and Caracol AM, a Milan-based additive manufacturing specialist. The project is positioned as a test case for broader industrial adoption of LFAM in the mobility sector, with both companies indicating plans to scale the approach.
Gregorio Delcò, Director of Strategy and Business Development at Caracol AM, is expected to share insights into the project during the “Disrupting Transportation” session at Formnext 2025 in Frankfurt.
