ROOF RACK SYSTEM FOR OFF HIGHWAY VAN
Project Overview
CAD, VENDOR MANAGEMENT, RESEARCH, BRANDING
Scope
After developing our new Off Highway Van brand language, I needed a flagship halo roof rack for the 2026 Model Refresh. My objective was to set our offerings apart from both market competitors and our sister company's accessory line. I replaced standard aftermarket bolt-on parts with a proprietary desogm that reinforced our position as a builder of premium, purpose-built vehicles.
My competitive analysis of external and internal offerings revealed three primary directives for the new design. Aesthetic Alignment: traditional tube and safari style racks offered functional benefits but 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: the vehicle's roofline geometry demanded a form-fitting profile for a high-end aesthetic.
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. During the sketch phase, I focused on maximizing available roof real estate while introducing modular elements to give customers a unique way to customize their vehicles.
Following a design-for-manufacturability (DFM) review, the base model of the roof rack is now in production. I built it from square tubing to streamline fabrication, cutting weight 15% at the vehicle's highest center of gravity compared to legacy racks. The modular system adapts to multiple van wheelbases and roof layouts, with integrated side and rear lighting and customizable forward setups. A fully clad iteration is currently undergoing final testing.
