Zone RV is revolutionising the caravan industry
In an industry that marries adventure and comfort, Zone RV stands tall as a beacon of innovation in off road caravan manufacturing.
Headquartered in an advanced manufacturing facility, located at Coolum Eco Industrial Park on the Sunshine Coast, Zone RV boasts the largest 3D printer in the southern hemisphere. It’s exactly what you’d expect from a brand that is synonymous with cutting-edge technology and forward-thinking designs.
Zone RV takes inspiration and technology from aeronautical and marine industries to ensure its vehicles can safely and reliably navigate further off the beaten track.
The Australian-made caravans are constructed using entirely composite materials, to guarantee both sturdiness and agility while boasting a range of innovative features. These techniques earned them the award for Best New RV at the 2023 caravancampingsales Innovation Awards.
Award-winning innovation
The winning entry was the Zone RV Expedition, a hybrid off road caravan that showcases the company’s commitment to pushing the boundaries of technology, design, quality and safety in caravan manufacturing.
Being touted as Australia’s first ‘3D printed’ caravan, the Zone RV Expedition seamlessly blends rugged durability with refined aesthetics.
Through the use of its large-scale 3D printer, Zone RV produced complex curved panels, that were strong yet lightweight, enabling an unparalleled level of fit, finish and structural integrity.
Pushing boundaries
A growing presence on the Sunshine Coast
Zone RV rapidly established itself as a leader in the Australian caravan market since its inception in 2016. What began as a venture offering DIY kit caravans has evolved into a thriving enterprise with over 200 employees and a reputation for some of the world’s most advanced caravans.
When the business outgrew its original 6,000-square-metre manufacturing facility in 2021, Zone RV acquired a nearby site to accommodate their burgeoning research and development endeavours.
As part of the company’s expansion, Zone RV added several state-of-the-art technologies to its toolkit including a 5-axis CNC machining and spraying system, a fibreglass cutting machine and a 50mW laser template projector and the show stopping 3D printer.
A global leader in RV-tech
Central to their innovative approach is an industry-leading printer, a colossal machine measuring 22 metres long, 5 metres wide and 2 metres high. This state-of-the-art 3D printing technology allows Zone RV to elevate the standard for precision and efficiency in caravan construction, producing completely custom parts that result in eye-catching and clever caravan designs.
Their use of composite materials for the body and cabinetry, which are significantly lighter than commonly used materials like timber and fiberglass, has made their caravans incredibly popular in the Australian market. This innovation not only reduces weight but also enhances durability and performance, appealing to a wide range of customers.
The popularity of Zone RV’s caravans is evident, with inquiries flooding in from Europe and America. In response to this growing international interest, the company is actively planning to take their product global, leveraging their technological advancements and unique design capabilities to capture new markets and expand their footprint worldwide.
A hub for manufacturing excellence
The decision to grow Zone RV’s operations on the Sunshine Coast is a testament to the region’s economic vitality and supportive business environment. With one of Australia’s fastest-growing economies and a reputation for innovation, the Sunshine Coast offers a compelling proposition for businesses looking to start up, scale up, or establish satellite offices.
The region is also one of the most sought after places to live in Australia with a rapidly growing population expected to reach 500,000 by 2042. The idyllic lifestyle, excellent amenities and 300 days of sunshine, attract a high calibre of professionals to the Sunshine Coast.
The future of off roading
Designed with the environment in mind
As a UNESCO Biosphere Reserve, the Sunshine Coast is a place where people and businesses champion sustainable development.
Zone RV’s commitment to the environment can be seen in both the business operations and product features. The use of a 3D printer produces less waste than other forms of manufacturing and because parts are printed on site there are reduced emissions from transport of materials.
The caravans themselves are also designed to minimise the environmental footprint while in use. The Expedition, for example, is equipped with environmentally conscious features, including a Redarc lithium battery system and rooftop solar panels. This self-sustaining power setup enables adventurers to traverse remote landscapes with confidence while using a cleaner energy option than a traditional generator.
As Zone RV continues to push the boundaries of what’s possible in caravan manufacturing, the company remains steadfast in its commitment to excellence, innovation and customer satisfaction. With its roots firmly planted in the Sunshine Coast community, Zone RV is poised to lead the charge towards a more exciting and sustainable future for the caravan industry.
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