Resin Infusion Manufacturing Transition
I successfully oversaw the transition of Earthcruiser’s fiberglass camper bodies from traditional wet hand-layup to vacuum infusion manufacturing. The project was driven by the need to reduce vehicle weight on a new Toyota Land Cruiser-based model, which was constrained by a 4.5t GVM to remain operable on a standard car licence. Reducing body weight was therefore critical to maintaining a practical payload.
Working with an experienced composite engineer, I helped translate a newly developed, FEA-validated lightweight layup design into a repeatable production process. I coordinated with experienced composite tradespeople, including shipwrights, and was responsible for developing and documenting the manufacturing methodology for future panels.
The transition was highly successful, achieving almost 50% weight reduction on the panel compared with the previous construction method, while providing improved consistency and quality. I also documented the R&D findings and developed detailed work instructions, creating a repeatable process that was successfully adopted for subsequent panel production.
