Phase 1

Goal

Create a credible, manufacturable concept shell that:

• proves feasibility
• attracts collaborators
• enables real quotes from builders
• and becomes the canonical reference for the project

Deliverables

1. Parametric 3D Shell Model

Tooling

• SolidWorks 2025
• Clean, readable feature tree
• Named variables
• No "vibe modeling"

Model scope

• Exterior shell geometry
• Interior void (hollow shell)
• Defined structural floor
• No furniture
• No windows cut
• No truck-specific mounts

2. Geometry Definition

Overall dimensions

All major dimensions must be controlled by variables.

Walls

• Flat side walls
• Vertical load-bearing surfaces
• No compound curvature in Phase 1

Roof

• Shallow structural crown (single-curvature)
• Front overhang extending forward over crew cab
  • parametrically defined depth
  • maintains roof profile/crown
  • standard in truck camper design

Floor

• Roof must include a shallow structural crown
• Purpose:
  • increase stiffness
  • reduce oil-canning
  • improve water shedding
• Crown must be:
  • single-curvature (one axis only)
  • symmetric left/right
  • defined by a variable
• No aesthetic sculpting in Phase 1
• No front–rear taper or styling features

Floor

• Floor must be explicitly modeled
• Acts as a structural diaphragm
• Flat plane with defined thickness
• Conceptually continuous with lower shell walls
• No subframe or mounting logic yet

3. Structural Intent (Concept-Level)

Not engineering calculations — design intent only.

Must clearly communicate:

• Shell is semi-monocoque
• Primary assumed load paths:
  • roof → walls
  • walls → floor
  • floor → base ring (future)
• Floor and roof are structural, not cosmetic
• Roof crown exists for stiffness, not aesthetics

This intent may be conveyed via:

• annotations in the CAD model
• section views
• a short written explanation

4. Manufacturing-Agnostic Design

The shell must not be tied to a single fabrication method.

The design must be compatible with:

• large-format additive manufacturing
• CNC foam core + composite laminate

Conceptual segmentation Even if modeled as a single body, the shell must be logically divisible into:

• roof
• side panels
• front panel
• rear panel
• floor

No redesign should be required to split these later.

5. Flange & Bonding Logic (Conceptual)

No detailed joints required — intent only.

Requirements

• Flange zones conceptually defined
• Typical flange width range: 30–50 mm
• Bond-first, laminate-over philosophy
• No reliance on mechanical fasteners for primary structure
• Compatible with:
  • glass fiber
  • carbon fiber
  • hybrid composite layups

Orientation of flanges is secondary at this stage; continuity and bond area are primary.

6. Export & Sharing Artifacts

The result must be shareable and reusable.

Deliverables

• Native SolidWorks files
• STEP export
• STL export (for miniature desktop printing)
• Variable table clearly documented