THE CAB – The first 3D-printed RV made from recycled polymer

LG Project Management chose to collaborate with Caracol AM to develop THE CAB, the world’s first functional fully 3D-printed mobile living module. Produced in a single piece thanks to Heron AM, Caracol’s robotic LFAM platform, this project showcases how advanced materials and LFAM processes can accelerate production, reduce environmental impact, and enable new design approaches in the RV and mobile living sector.

Large-format additive manufacturing (LFAM) is introducing a paradigm shift across multiple industries, offering design freedom, efficient material use, and the ability to integrate recycled feedstocks into high-performance products. Beyond the technology, achieving successful real-world applications requires a deep understanding of the entire workflow — from design, to materials, to production, and post-processing — to ensure industrial scalability and compliance with sector standards. This project marks a revolutionary milestone thanks to the collaboration between LG Project Management, a Swiss company focused on innovative mobility solutions, and Caracol AM, leveraging the Heron AM robotic platform to produce a monocoque RV with a fully digital design-to-print workflow.

Manufacturing parameters and benefits

The project was developed with a long-term vision, analyzing each step of the workflow to establish the foundation for future industrialization. The choice of a recycled PET-based polymer reinforced with glass fiber and UV-resistant properties ensured the mechanical, thermal, and fire-retardant performance required for outdoor and mobile applications. By printing the monocoque in a single, uninterrupted process, the need for traditional fiberglass molds, adhesives, and multi-component assemblies was eliminated. This approach not only improved structural integrity and watertightness but also reduced environmental impact, achieving a 60% reduction in material waste.

In particular, the optimization of the process made it possible to produce a single piece monocoque, completely avoiding assemblies. This innovation resulted in a waste reduction of around 60% compared to fiberglass lamination methods, and a significant lead time reduction — just one week with LFAM versus approximately three months with traditional production.

Key facts

• System: Heron 400 HF rail
• Nozzle size: 8 mm
• Material: rPETG GF UV resistant
• Printing time: 92 h
• Weight: 660 kg
• Dimensions: 4300 × 2100 × 2100 mm
• Post-Processing: sanding and painting

Innovation in design & production methods

The digital workflow enabled by Caracol’s Heron AM platform allowed engineers to integrate cavities and channels directly within the printed RV, simplifying the installation of electrical, plumbing, and heating systems. This feature reduces both production time and potential points of failure compared to traditional RV structures.

Weighing 660 kg, the monocoque ensures mobility efficiency while maintaining robustness against mechanical stress and vibration. Its design supports multiple configurations — from camper to mobile office, tiny home, or floating living unit — highlighting the flexibility and scalability of LFAM in creating tailored solutions for different lifestyles and markets.

A promising future for sustainable mobility

THE CAB is a tangible example of how additive manufacturing can accelerate innovation in the RV and mobile living industry. By combining advanced materials with Heron AM technology, the project demonstrates the feasibility of building highly customizable, sustainable, and road-ready living modules in a fraction of the time required by traditional methods.

LG Project Management and Caracol AM are committed to pushing this approach toward industrialization, paving the way for more scalable, circular, and accessible production models. This achievement marks the beginning of a new era for mobile living solutions — one where technology, sustainability, and design freedom converge to redefine how people create and experience their personal spaces.

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