Zone RV Expedition: Australia’s First 3D-Printed Off-Road Caravan Redefines Adventure Living
Australia’s love affair with the great outdoors and rugged off-road adventures has given rise to countless innovative RVs. But standing at the forefront of this movement is the Zone RV Expedition, a revolutionary caravan that is not only engineered for the harshest terrains but also proudly holds the title of Australia’s first 3D-printed caravan. This hybrid travel trailer perfectly blends luxury and toughness, offering explorers an unparalleled way to enjoy remote landscapes without sacrificing comfort.
Zone RV, a brand that emerged in 2015, has quickly built a reputation for innovation, quality, and design excellence. Originally offering DIY caravan kits, the company now leads the industry with advanced composite materials and manufacturing techniques inspired by the marine and aerospace industries. Operating from the Sunshine Coast, Zone RV boasts the largest 3D printer in the Southern Hemisphere—an achievement that helped create the groundbreaking Expedition series. In fact, the Expedition was crowned Best New RV at the 2023 caravancampingsales Innovation Awards, proving just how impactful this design has become.
Unlike traditional caravans that excel only on highways, the Expedition thrives off the beaten path. Its rugged design features a compact footprint, aggressive departure angles, and a pop-top roof that lowers the van’s travel profile, making it aerodynamic and able to access areas with low clearance. Whether tackling corrugated Outback roads, navigating tight bush trails, or even handling rocky creek crossings, this caravan is built for true adventure.
Two versions are available: a soft-top and a hard-top. Both showcase curved panels crafted by advanced 3D-printing methods, offering lightweight yet incredibly strong structures that eliminate the need for traditional timber. These composite walls and roofs are vacuum-molded with techniques taken from high-tech yacht building, delivering unmatched durability and thermal efficiency. Reinforced with aluminum panels, the furniture and interiors inside are equally robust, ensuring this rig lasts in extreme conditions.
Underneath, the hot-dipped galvanized chassis, polyethylene coating, and Cruisemaster ATX Unleashed suspension provide bulletproof reliability. With 17-inch all-terrain wheels, hydraulic disc brakes, and three 100-liter freshwater tanks mounted high for clearance, the Expedition is as functional as it is stylish. Add in features like stone guards, modular receivers, Maxtrax recovery boards, and waterproof storage, and you’ve got a rig that is fully prepared for the wild.
The exterior also highlights an impressive outdoor kitchen setup, featuring a dual induction cooktop, microwave, large fridge, BBQ slide, pantry, and sink—all designed for those who prefer to dine under the stars. Combined with a robust awning, rear storage mounts, and solar-ready rails, it’s the perfect base camp for long adventures.
Inside, luxury awaits. At the touch of a button, the electronic pop-top raises to create a spacious interior with 6.7 feet of headroom and panoramic windows. The floor plan is intelligently designed, with a queen-size north-south bed up front, a central lounge and kitchen area, and a rear bathroom featuring a shower, composting toilet, and optional washing machine. For families, optional upgrades like fold-down beds can expand its capacity to sleep four.
Off-grid capabilities are equally impressive. With 1080W of solar power, an 800Ah battery bank, a 3,000W inverter, and REDARC electronics, the Expedition provides serious independence. A 300-liter fresh water supply, diesel-powered heating, hot water, and air conditioning make sure adventurers can live comfortably no matter how remote the journey.
Starting at AUD $158,000, the Zone RV Expedition is more than just a caravan—it’s a statement of innovation and freedom. Designed for those who crave adventure but demand luxury, it proves that cutting-edge technology and rugged durability can coexist in the world of off-road caravanning.
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Zone RV Expedition: Australia’s First 3D-Printed Off-Road Caravan Redefines Adventure Living
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