Engineering of a Class B+ RV with an all-new composite body structure, including full durability simulation of the body, chassis, and sub-frame for optimal weight reduction.

• Designed and mounted fiberglass sandwich composite body on OEM cutaway with extended rear frame.
• Built a full vehicle FE model integrating chassis, custom frame extensions, suspension, wheels, and composite body.
• Developed detailed finite element models of:
  • OEM cutaway chassis
  • Custom chassis extensions in the back with suspension, axle and wheels
  • Body cage (Pultruded structural body members, Fiberglass outer skins)
  • Modeling of adhesive joints and specialty fasteners
• Conducted modal and durability analyses to identify high-stress zones.
• Performed structural improvements and weight optimization for subframe and chassis extensions.
• Evaluated tow hitch integration and extended frame performance.
• Implemented design refinements based on simulation results to meet structural performance and safety targets.