Overview

This document defines the OpenOverland shell as a standalone architectural object.

The shell is the core of the OpenOverland project. All other systems — vehicle integration, interiors, electrical, and manufacturing — attach to or depend on it. For this reason, the shell is designed first, in isolation, with clear boundaries and explicit intent.

This is a conceptual and architectural specification, not a fabrication manual.

Purpose of the Shell

The shell exists to provide:

• Structural enclosure
• Environmental protection
• Long-term durability
• A stable interface for systems and interiors

The shell is not:

• A vehicle-specific component
• A finished interior
• A decorative body
• A load-bearing replacement for a subframe

The shell must remain valid even as vehicles, systems, and fabrication methods change.

Design Posture

The shell is conceived as a monocoque or semi-monocoque structure, where geometry and surface continuity provide stiffness and durability.

Key assumptions:

• Curvature is structural, not cosmetic
• Continuity matters more than localized reinforcement
• Load paths should be global and predictable
• The shell should tolerate vibration, fatigue, and repair

The shell should not depend on furniture, cabinetry, or interior components for structural integrity.

Geometry

The shell geometry prioritizes:

• Smooth curvature
• Minimal sharp transitions
• Predictable surface flow
• Manufacturability across multiple processes

Flat panels are avoided where possible. Where flat regions exist, they are intentional and limited.

The geometry is defined to:

• Distribute loads across surfaces
• Reduce stress concentrations
• Improve resistance to torsion and racking
• Support walkable roof surfaces where appropriate

Exact dimensions are intentionally parametric and not fixed at this stage.

Structural Concept

The shell is designed as a self-supporting enclosure.

Structural behavior is achieved through:

• Overall form
• Surface curvature
• Section depth
• Material separation (in sandwich constructions)

The shell:

• Carries its own loads
• Transfers loads through its geometry
• Does not assume structural contribution from attached systems

Localized reinforcements may exist, but they do not replace global structural behavior.

Parametric Design

The shell is fully parametric.

Key characteristics:

• Major dimensions are defined by named variables
• Geometry adapts predictably to dimension changes
• Feature trees are clean, ordered, and intentional
• No “dead” or hard-coded geometry exists in core files

Parametric intent is prioritized over geometric convenience.

The goal is not infinite configurability, but controlled adaptability.

Interfaces

The shell defines interfaces, not implementations.

Interfaces include:

• Base interface (where the shell expects support)
• Roof interface (for loads, access, or attachments)
• Interior interface (for non-structural attachments)
• Penetration zones (windows, doors, hatches)

Interfaces are:

• Explicit
• Documented
• Conservative

The shell does not assume how these interfaces are used — only that they exist.

Manufacturing Neutrality

The shell geometry is designed to be compatible with multiple fabrication paths, including:

• Large-scale additive manufacturing
• Foam-core composite layups
• Hybrid approaches

No single manufacturing method is assumed or required.

Manufacturing constraints are documented separately and must not drive core geometry prematurely.

What This Document Is Not

This document does not:

• Specify wall thicknesses
• Select materials
• Define laminate schedules
• Address vehicle-specific mounting
• Define interior layouts

Those concerns are intentionally deferred.

Completion is defined by architectural clarity, not by production readiness.

Closing Notes

The shell is the foundation.

If the shell is correct, everything else can evolve. If the shell is compromised, no amount of system refinement will fix it.

This document exists to ensure the shell is treated as an architectural object, not a container.