Problem - Our camper vans lacked a durable external storage system that could be used for bulky or dirty gear. A system that can also mount to our existing rear rack system without interfering with spare tyres or an external fuel can. 

Constraints 

• Compatible with existing rear rack systems

• Exposure to weather and elements

• Cost targets to stay competitive

• Ease of fabrication and installation

Engineering Work - I took the lead on this project, utilising CAD to develop multiple design iterations that focused on rigidity, material efficiency, and manufacturability. I worked around design limitations due to the sheet metal brake. Choose a material of 0.08” 5052 Aluminium to keep unit weight below 50lbs, support a load of 150lbs, and a cost below $1000. A wrinkle black powder coat was applied for durability. Basic stress analysis and hand calculations were performed to size panels and hardware for expected loads and daily use. 

Prototyping & Validation - Prototypes were fabricated and assembled to evaluate fit, alignment, and ease of installation. Durability and load capacity were tested through real-world handling and exposure. Design updates were performed based on real-world feedback from fabrication and installation. 

Outcome - The final design received positive customer feedback. Proper documentation was created, including CAD drawings, BOMs, quotes, packaging instructions, and cost analysis. Providing a proper transition from prototype to product. 

Problem - The small profile of the boost box mini meant that when mounted to the van, there was waisted space on top of the box. Therefore a storage basket was needed to be mounted on top of the box, providing a space to sore additional items. 

Constraints 

• Compatible with Boost Box Mini

• Exposure to weather and elements

• Cost targets to stay competitive

• Ease of fabrication and installation

Engineering Work - Similar to my other projects, this started with research into similar products for inspiration and to create initial design sketches. Followed by a design on CAD integrating functionality, manufacturability, durability, and ease of installation.

Outcome - The final design was recieved well. Afterwards the design was translated to drawings, along with a BOM used for price analysis and quoting with our local suppliers. 

Problem - Our Mercedes Sprinter vans typically lacked sufficient storage in the cab area, due to the center walkway between seats. For this reason I was given the task to design, test, and manufacture a folding table to live between the seats while still being able to be folded and stored behind the driver seat. 

Constraints 

• Sturdy fitment to seat to minimize vibrations during driving

• Minimal part for ease of install and manufacturing

• Components able to cut on the in-house CNC machine

• Competitive price. 

Engineering Work - I began this project with research and taking measurements to understand the constraints and gauge several design choices with simple sketches. Afterwards a CAD model is created and verified, the parts are then cut on the in-house CNC machine. 

Prototyping & Validation - This prototype is then tested, taking note of changes to make. This changes came about by repeated testing and simulated day-to-day use of the product, identifying  This then followed by the creation of several more prototypes before the final version is verified and ready for marketing. 

Outcome - Proper documentation was created for BOMs, Quotes, Packing Lists, R&D, packaging, COGS, and a Competitive Analysis.

Problem - A proper rear step for our camper vans was needed. Designed to be safe, functional, and aesthetic. As difficulties getting into the rear of the van where bought up by customers. 

Constraints 

• Sturdy fitment to the rear frame of the Sprinter Van

• Exposure to weather and elements

• Cost targets to stay competitive

• Ease of fabrication and installation

• Aesthetically pleasing 

Engineering Work - Taking ownership, I began working by designing a basic overall design that matched the proper aesthetic. Using CAD, I created multiple design iterations. Designed to support 300lbs of static load, with an overall cost below $900. The design incorporated reinforced mounting points to the frame using grade 8 Hardware, a textured, non-slip surface for safety, and a sleek, low-profile look that complemented the van’s style. 

Prototyping & Validation - After modelling, prototyping was done while working with fabricators who gave insight and feedback into fabrication capabilities, like tube bending, and optimal methods of assembling. This was followed by real-world testing to ensure strength and longevity. 

Outcome - Proper documentation was created for BOMs, Quotes, Packing Lists, R&D, packaging and shipping, COGS, and a Competitive Analysis. The final product provided a cost-effective and visually cohesive solution, enhancing both usability and the overall design of Sandy Vans’ camper builds.

Problem - Many customers requested a storage locker to be installed in a van. Giving the ability to provide a reliable storage for valuables. 

Constraints 

• Provide a secure storage for valuables

• Exposure to weather and elements

• Cost targets to stay competitive

• Ease of fabrication and installation

Engineering Work - After some research, a void in the body work was discovered in all sprinter vans, and therefore was chosen for an ideal spot for the storage system. I took the lead on this project and used CAD to design an initial prototype. Working around constraints, to keep costs below $300, develop a secure latch and hinge, and create a simple assembly. Working closely with fabrication teams, I used a sheet metal design to minimise cost, with 0.9” 5052 Aluminum and a black powder coat for strength and durability. Along with basic hardware and hinges, the installation is easy for the customers.

Prototyping & Validation - Prototypes were fabricated and installed to evaluate fit, alignment, and ease of installation. Durability was tested through real-life everyday use. Stress tests were performed to evaluate the strength to ensure resistance to any break-in attempts. 

Outcome - Due to its cost and ease of installation, the final design received positive customer feedback. Proper documentation was created, including CAD drawings, BOMs, quotes, packaging instructions, and cost analysis. Providing a proper transition from prototype to product. 

Problem - A new form of storage was introduced in the form of molle panels, which were mounted vertically to surfaces, providing storage options to otherwise unused space. Therefore, a viable product was needed to bring this storage solution to customers. 

Constraints 

• Sturdy fitment to the rear doors of the van

• Cost targets to stay competitive

• Ease of fabrication and installation

• Aesthetically pleasing 

Engineering Work - For this project, I began work by determining the mount location to create an overall design of the panel. Next steps involved determining the optimal material and thickness to be ⅛” thick 5052 Aluminum, balancing rigidity and cost. The panel must be able to support 20lbs without deformation. Stress tests were performed to determine this optimal thickness. Designs were created in CAD with test pieces made primarily with wood to reduce cost and speed up prototype iterations. Next, hardware mountings were tested to determine the best option for strength and ease of installation.

Prototyping & Validation - Test pieces were cut out of wood using a CNC machine in order to test sizing and hole placement. Afterwards, pieces were laser cut from aluminium sheets. I worked with the installation team to create the ideal install process and instructions, as well as receive any input from them. 

Outcome - The final product was received well by customers and provides a great option to utilise wasted storage. As a result, nearly all Sandy vans came installed with these panels. Afterwards, proper documentation was created for BOMs, Quotes, Packing Lists, R&D, Packaging & Shipping, and COGS. In order to make the product official, I also conducted a competitive analysis with similar products to gauge pricing. 

Problem - A common issue seen not only in campers, but also in any vehicles that tow. Is constantly hitting your shins on the hitch when not in use. Therefore, for our vans, we decided to create a bracket to store the hitch underneath the bumper when not in use. 

Constraints 

• Sturdy fitment to the frame of the Van

• Durability when exposed to weather and elements

• Securely hold the hitch

• Cost targets to stay competitive

• Low cost and simple installation

Engineering Work - I took the lead to design the bracket, which was done by measuring the vehicle interface and using customer feedback to determine the optimal location. Next, CAD was used to create an initial design to balance strength, manufacturability, and ease of installation. 0.19” aluminium was chosen due to strength and weight, as the bracket must hold the hitch when exposed to the elements, like dirt and rocks. With a close collaboration with fabrication and installation teams, we choose the proper hardware choice and assembly strategy. 

Prototyping & Validation - Multiple prototypes were fabricated and tested to evaluate fit, accessibility, and real-world use. Design changes were made, including hole placement and mounting options to handle different-sized hitches. 

Outcome - The final design was put into production with the best overall solution. Complete documentation was generated, including drawings, BOMs, supplier quotes, packaging, cost analysis, and competitive research.