Finalist 2023

World-First Monocoque Electric Caravans

Ben Liu

The World-First Monocoque Electric Caravan is the caravan equivalent to a premium luxury car. Constructed in a one-piece monocoque structure.

The World-First Monocoque Electric Caravan is the caravan equivalent to a premium luxury car. Constructed in a one-piece monocoque structure, it has no mechanical joints and features patented monocoque technology and a patented power system.

Design Brief:

While the car industry has long embraced monocoque construction, the caravan industry has predominantly adhered to outdated practices. Conventional caravans are constructed by attaching wall panels to a chassis using a multitude of trims, parts, glues, and screws. This approach often leads to inherent issues such as water leaks and driving instability caused by body movements.

To overcome these challenges, we have developed a revolutionary design solution: a caravan built in a one-piece monocoque structure using robotic welding. This unique approach eliminates the need for mechanical joints, glues, screws, bolts, and trims. The result is a sleek, auto-like finish that offers unparalleled strength and durability, particularly when navigating tough off-road terrain


This project was developed by:

Ben Liu

Design Process

Unlike the car industry, most caravans are built using age-old body on chassis production methods since last century until today, putting wall panels on the chassis to form a mobile home and trying to fix everything together by using hundreds of trims, parts, glues and screws. It brings many inherent issues to the caravan because of this way of doing it, like water leaks, driving instability caused by body movements etc.

Our design solution was to build a caravan in monocoque using robotic welding forming a one-piece structure for the body and chassis creating a unique caravan with a smooth, auto-like finish. No more mechanical joints, no glues, screws, bolts and trims to fix the bits and bits together.

Design Excellence

Currently the majority of caravan bodies are manufactured using a labour-intensive complex and ancient system of stapling a ply onto a meranti timber frame which is then assembled by using screws and bolts onto a chassis which is then connected to the fronts, backs and roof.

After this process is done then insulation is added and aluminium sheets or alucobond type stapled onto the meranti frame.

Fibreglass or aluminium sheets are used for the roof. These are connected by multiple H moulds, J moulds. Thousands of human interactions and possibilities of error and failure.

Harvok has eliminated virtually all these potential failures by investing in robotic building and modern engineering thereby manufacturing Australia’s most modern built caravan.

Built as a monocoque which ensures that there are no joints in the whole body. No H moulds, no J moulds, no joints at all.

By eliminating all these items, we actually deliver the customer a superior product.

Our innovative design has far-reaching implications for customers in the caravan and RV industry. By mitigating labour involvement, reducing the number of parts, and enabling more standardized manufacturing processes, our technology benefits all caravan buyers. It resolves long-standing issues, such as water ingress, rotten timbers, silicone aging, rust, and ongoing maintenance concerns, which have plagued caravan owners for decades. The introduction of our one-piece monocoque body marks a new era of reliability and customer satisfaction.

Design Innovation

We are thrilled to present the World's First Monocoque Electric Caravan, a groundbreaking innovation that sets a new standard for design and manufacturing excellence. Unlike traditional caravans, which rely on age-old body-on-chassis production methods, our caravan is built using patented Monocoque Technology, mirroring the construction techniques found in modern motor vehicles.

While the car industry has long embraced monocoque construction, the caravan industry has predominantly adhered to outdated practices. Conventional caravans are constructed by attaching wall panels to a chassis using a multitude of trims, parts, glues, and screws. This approach often leads to inherent issues such as water leaks and driving instability caused by body movements.

To overcome these challenges, we have developed a revolutionary design solution: a caravan built in a one-piece monocoque structure using robotic welding.

Design Impact

Being a full electric caravan, it eliminates gas appliances from the caravan. It makes the camping greener, safer and more sustainable.

Equipped with our patented 48V power system, the caravan offers a standard 10 kWh battery capacity, upgradable to 15 kWh, similar to the Tesla Wall. This onboard power system empowers travellers to engage in free camping without relying on the power grid, all while enjoying the comforts of home, including the use of kettles, coffee machines, air conditioning, and induction cooktops. With 1000W of solar panels on the roof to harvest as much solar energy as possible.

Our design innovation extends beyond improving the user experience. It addresses the environmental impact of conventional caravan manufacturing practices. Meranti timber, a commonly used material in caravan construction, relies on unsustainable and illegal logging practices in Southeast Asia, threatening valuable biodiversity.

By eliminating thousands of staples, litres of glue, 50 tubes of silicon average per caravan our monocoque caravan offers a superior product while significantly reducing the environmental footprint.

As climate change intensifies weather patterns, heavy rains pose a significant challenge for traditional caravans with multiple joints and weak points. In contrast, our monocoque caravan significantly reduces the entry points for water ingress, minimizing the risk of rot and mould. Customers can have peace of mind knowing that their caravan is built to withstand even the harshest weather conditions.

Water will always find the weakest spot of a screwed, glued and silicone made caravan with many joints. Our customers can be rest assured as our monocoque caravan will only have entry points for water ingress from the air conditioner and hatches on the roof or windows on the side which is a miniscule amount compared to a conventional built caravan.

Circular Design and Sustainability Features

We are proud to present the World's First Monocoque Electric Caravan, an innovation that not only revolutionizes the caravan industry but also embodies the principles of circular design and sustainability. Built with a one-piece monocoque structure, our caravan eliminates the need for timber frames, glues, and silicon, materials that pose challenges to the environment due to their limited recyclability and decomposition capabilities.

By opting for a monocoque body, we have created a caravan that offers exceptional durability and longevity throughout its service life. The absence of environmentally unfriendly materials makes it easier to recycle the caravan once it reaches the end of its useful life. Unlike traditional construction methods that rely on a combination of materials, our monocoque design utilizes metals, which can be efficiently and effectively recycled, contributing to a more sustainable and circular economy.

In addition to its positive environmental impact, the monocoque construction offers numerous benefits. The caravan's longevity reduces the need for frequent replacements, minimizing resource consumption and waste generation. Furthermore, the elimination of timber frames, glues, and silicon significantly reduces the caravan's environmental footprint, making it a more sustainable choice for conscious consumers.

Our commitment to sustainability extends beyond the materials used in construction. As a full electric caravan, our design eliminates the need for gas, making camping experiences greener and more sustainable. The incorporation of 1000W of solar panels on the roof maximizes the utilization of solar energy, further reducing reliance on external power sources and minimizing the carbon footprint associated with traditional energy generation.

Meranti timber is a very common material used in caravan manufacturing in Australia. It is a tropical rainforest species found throughout South East Asia. Eliminating meranti timber completely from our design directly impacts these rainforest species.

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