Highland Vans: Elevating Adventure with Innovative Design and Engineering

Highland Vans started with a mission to produce the ultimate exploration vehicle. Blending their expertise in engineering, technology, and interior design with a deep love for the open road and adventure, the founders have since redefined mobile living through their bespoke adventure camper vans. Their company specializes in converting Mercedes Sprinter®, Ram Promaster®, and Ford Transit® chassis into luxurious, durable adventure campers on wheels. Highland Vans stands out for its customized and modern design approach with the built-in ruggedness for the rigors of travel.

“Early on, our models were very basic,” explains Szymon Gluc, Highland Vans Principal Design Director. “[But now,] using the [SOLIDWORKS®] software, we are able to utilize every little inch and curve of the van to develop precise-fitting parts that work every single time.” The parts are manufactured at the company’s plant, located outside Chicago, and compatible across multiple vehicle platforms. Highland Vans’ design flair, which uses various materials and finishes to develop a unique design style that blends adventurous styling with a modern, sophisticated, home-like feel inside the vans, sets the company apart from other adventure camper van builders.

“I think the most important aspect of SOLIDWORKS is being able to visualize different ideas and concepts to customers so that they can actually see [in 3D] what they’re gonna get,” says Gluc. “We use the software to add colors and create beautiful renderings of their dream van, allowing our clients to visualize the final product.”

As the company grew, so did the number and complexity of parts. The engineering team struggled to manage and organize the numerous design files. However, by implementing the 3DEXPERIENCE® platform, they were able to overcome these challenges because they could easily categorize and store different parts and designs with bookmarks on the platform, which streamlined their processes and improved overall efficiency.

“We had over 13,000 parts in our cloud library,” notes Highland Vans Lead Industrial Designer Umair Yusufi. “With SOLIDWORKS Connected, we’re able to organize in a much better way now that we know who is working on what and when.” He continues, “If Szymon is working on something and he has to stop, I can see [where he left off] and start working on it from there without really changing anything because we have the same tools and setup.”

Leveraging the streamlined workflow enabled by SOLIDWORKS Connected, Highland Vans has seen additional advancements in its manufacturing capabilities via the DELMIA Shop Floor Programmer role on the 3DEXPERIENCE platform. The role is specifically aimed at making it easier for machinists and operators to create, modify, and simulate NC programs. This capability is intended to reduce the time between design and production, enhance the accuracy of the machining processes, and improve overall efficiency on the manufacturing floor. The Shop Floor Programmer tools enable precise part production and efficient nesting processes, reducing material waste and minimizing cutting time.

“DELMIA [Shop Floor Programmer] has improved the way we nest files and produce parts,” explains Yusufi. “It has enhanced turnaround times and reduced errors, because now we can not only nest, but also efficiently make changes before cutting.”

The company had previously used Autodesk Fusion 360® for manufacturing, which requires users to nest parts manually. Yusufi continues, “Imagine building five vans at one time, and I have to cut drawers—that adds up to 100 boxes. Then, I manually orient them on a machine, and I need to [manually] make sure I'm not wasting a lot of material while cutting and nesting those parts—that takes a lot of time.” DELMIA [Shop Floor Programmer] significantly streamlines the part nesting process in manufacturing, allowing Highlander Vans to design a part once and automatically nest it multiple times, saving both time and materials. 

“No matter if you orient a part or add a feature, DELMIA [Shop Floor Programmer] automatically nests according to our requirements,” details Yusufi. “It makes the process very efficient. I remember nesting for four hours for one van. Now it’s literally within 10 minutes. It’s done automatically, optimized, and it provides reports that specify time and cost and more.”

Using the DELMIA Shop Floor Programmer on the unified 3DEXPERIENCE platform has rocketed Highlander Vans efficiency in producing van parts, even when requirements vary. “The software allows one person to design a part while another provides feedback without modifying any features or designs,” he adds. Everyone can access, view, and interact with the part without making any changes, which has been tremendous. I love the software.”

Understanding and fulfilling customer desires is central to Highland Vans’ business model. By visualizing different configurations and customizations through SOLIDWORKS, customers can see potential designs before the build begins, which ensures their satisfaction with the final product. This visualization capability is not just a tool for accuracy; it’s part of the customer engagement experience that allows clients to interact with and modify their designs in real time.

Through continuous research and development and a keen understanding of their clients’ needs, Highland Vans is set to keep leading the way in van conversion innovation, providing adventurers with reliable, stylish, and comfortable homes on the road.