Case Study: Jerba Campervans — Bespoke Production Made Simple
When it comes to crafting unique, high-end campervan conversions, Jerba Campervans (specialists in VW van transformations) prides itself on attention to detail, craftsmanship, and safety. Custom interior components must not only look premium but also perform like those from mass-produced vehicles.
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The Challenge: Quality Parts Without Costly Tooling
Jerba faced a familiar hurdle: sourcing custom, high-quality parts in low quantities. Traditional injection moulding delivers the visual and functional finish they needed—but at an impractically high cost and with long lead times—particularly challenging for low-volume, bespoke projects.
The Solution: Additive Manufacturing to the Rescue
To overcome these constraints, Jerba turned to additive manufacturing. Their in-house team first produced prototypes for testing form and fit. Once validated, they partnered with SGD 3D to scale into production.
Material & Process:
- Selective Laser Sintering (SLS) using Nylon PA12 GF (glass-filled) was chosen for its strength, precision, and smooth finish—perfect for replacing traditionally moulded parts
- Modular Design proved invaluable—components could be tailored for different van layouts without redesigning the entire part
Aesthetic Upgrade via Vapour Smoothing
While SLS delivered functional excellence, the raw nylon finish didn’t match Jerba’s interior standards. To achieve a polished, moulded look, vapour smoothing was applied. This process:
- Softens porous surfaces into a sleek semi-gloss finish
- Reduces friction for moving components
- Creates a cleaner, moisture-resistant surface
- Enhances durability by sealing the outer layer
Visual Comparison:
| Stage | Surface Quality |
|---|---|
| Before Vapour Smoothing | Matte and slightly rough (typical SLS) |
| After Vapour Smoothing | Smooth, satin-like finish resembling injection moulding |
Key Project Details
- Part: Corner End Profile
- Technology: Selective Laser Sintering (SLS)
- Material: Nylon PA12 GF (Glass-Filled)
- Finish: Vapour Smoothed (PostPro Pure)
- Quantity: 100 units
- Lead Time: 10 working days
Outcome & Insights
Jerba successfully produced high-quality, functional corner parts that met stringent visual and mechanical requirements—without the time or cost burden of tooling. This highlights how 3D printing delivers precision, flexibility, and efficiency—even for small-scale production runs