Commonly used joints, actuators and manufacturing process

Even though the flexi-fold-out is a novel patent pending design we have used as many off the shelf parts as possible so it is easy to manufacture and maintain.

• The core joints are commonly used and highly tested hinges and linear bearings

• The actuators are high quality mass manufactured linear actuators

• The sensors, wiring looms and electronics are custom made but use commonly techniques for safety and control eg current sensors to detect an obstacle (similar to a garage door opener)

• Outdoor fabric that can be sourced from a range of quality manufacturers

• Avoiding moving weather seals that are typically a weak point in slide-outs

• Precision CNC fabrications, robotic welding and powder coating for quality control

• High quality fiber glass external structure to maintain aerodynamics and keep weight low.

• No novel manufacturing technologies so we can rely on the long tested processes of some of the worlds best manufacturers.

• All parts of the flexi-fold-out are designed to be easily swapped if they need to be replaced or repaired.

Tested to ensure reliability and robustness

When purchasing a key part of your van you want to know that it has been well tested and totally reliable. Below is a list of some of the testing we have done.

• Decades worth of folding and unfolding to see if there is any wear and tear in the key mechanisms etc

• Accelerated vibration testing on shaker tables to see how the mechanism performs on the worst roads you are likely to encounter.

• Destructive testing of some key components

• Water proof testing both with high pressure hoses and outside.

• Wind testing is hard to simulate but we have tested in the wind up to …. Without a problem.

• Lots of real world testing as well - taken it to some pretty cool places.

Safety

All parts of the fold down and up are designed to be able to work in 3 modes, fully automatic, manual/electric for fully manual (i.e. with no power at all).

Additional considerations include

• The key heavy part of the mechanism is nicely balanced so even without power one person can lift it into place.

• All actuators have current sensors to detect obstacles - similar to how auto garage door openers work

• Operation via the remote control is designed so that a person has to be there watching the fold up and fold down.

• Key back mechanism is held with 3 independent system to ensure it is secure when travelling

• The key mechanisms alert others around that something is happening.

• Sensors detect and alert if not latched correctly

Leverage the high quality existing van Van engineering

The Mercedes Sprinter is a beautifully engineered vehicle and we wanted to make sure we can make the most of its design features.

• The flexi-foldout does not require any modification to the body of the vehicle.

• The structure is supported by the robust towbar mounts and secured by the existing van door hinge bolt holes.

• The existing door seal is used to ensure a waterproof seal.

• All of the parking sensors, cameras, lights etc are also used so the same great driving features are available

• The back is designed not just to keep the visual aesthetic but it is also key to good aerodynamics that improves fuel efficiency.

Environmentally friendly

High quality engineering when done right can also improve the environmental friendliness of products.

• More fuel efficient. A 7.5-8 m motor home typically uses 60-100% more fuel than a 6m van. If you are going electric then that is twice the range and either way a vastly lower carbon footprint .

• Lower weight for the same usable space. A 7.5-8m motor home can be 1-2 tonnes heavier than a 6 m vehicle. This is a massive amount of extra stuff that needs to be manufactured and dragged around with you reducing your driving performance