The design process occurred over a number of years and involved various stages.
Research: Market research and competitor review including four berth camper trailers and camper trailers utilising composites. This process led to the definition of specifications including basic layout and functionality.
Packing Studies: CAD design of the basic layout involving packaging of necessary componentry and concept design of moving assemblies. This work defined the physical design envelope of the product. Styling Studies: Design of exterior and interior cosmetic surfaces within the design envelope. This involved further CAD based work along with hundreds of photo realistic computer renders to assess and iterate the styling. A full scale mock-up of the camper was constructed to confirm (and improve) the virtual models.
Engineering: Structural engineering with methodologies such as finite element analysis to define the mechanical load bearing components of the camper to ensure sufficient integrity and durability.
Prototype: Construction of a hand-built operation prototype to confirm functionality and provide a durability test platform.
Testing and Redesign: Instrumentation and physical testing of the prototype under typical usage scenarios. Including thousands of kilometres of harsh outback towing. Inspection and review of resultant performance and identification of underperforming components. Design iteration where needed.
The first few design requirements have been clearly satisfied. The Kerfton Fouray provides internal bedding for 4. It can be setup by one person in under 5 minutes, making it one of the fastest compact 4 berth tent top camper trailers on the market. Its compact and lightweight at 1150kg tare fully optioned. Response to the products aesthetics is subjective, but overwhelmingly positive. Numerous customer enquiries have been received both from within Australian and internationally. Many of these enquiries are based purely on a positive response to the aesthetics of the product.