ROOF RACK SYSTEM FOR OFF HIGHWAY VAN
Project Overview
CAD, Vendor Management, Research, Branding.
Scope
Following the development of the new Off Highway Van brand language, the 2026 Model Refresh required a flagship halo roof rack. The objective was to distinctly separate the brand's offerings from both market competitors and a sister company's accessory line. By replacing standard aftermarket bolt-on parts with a proprietary, highly engineered system, the roof rack reinforces the company's position as a builder of premium, purpose-built vehicles.
Competitive analysis of external and internal offerings revealed three primary directives for the new design: Aesthetic Alignment: While traditional tube and safari style racks offered functional benefits, they conflicted with the established Off Highway Van design language. Volume and Integration: Existing internal rack solutions failed to maximize the available spatial envelope and lacked a cohesive, purpose-built appearance. Premium Fitment: Achieving a high-end aesthetic required a form-fitting profile that tightly contoured to the specific geometry of the vehicle's roofline.
I drew on the founder's experience in Porsche and Corvette racing and the company's "Build it Light" ethos to develop a roof rack that stands out in the market. The sketch phase focused on maximizing available roof real estate while introducing modular elements to give customers a unique way to customize their vehicles.
Following DFM, the base model of the roof rack is now in production. Constructed from square tubing to streamline fabrication, the final architecture reduces weight by 15% at the vehicle's highest center of gravity compared to legacy racks. The modular system adapts to multiple van wheelbases and roof layouts, featuring integrated side and rear lighting alongside customizable forward setups. A fully clad iteration is currently undergoing final testing.
