About the Client

A U.S.-based recreation vehicle (RV) OEM known for delivering high-end, customizable products. The client aimed to refresh the exterior design of a new RV model while minimizing changes to existing structures and maintaining production feasibility.

The Challenge

The client required a redesigned front cap for a new vehicle that visually differentiated it from earlier models, while retaining the existing underlying structure and maximizing part reuse. The new design needed to meet both engineering and brand styling goals under a tight schedule.

Key challenges included:

• Delivering a brand-new aesthetic using carryover structural elements
• Balancing design intent with airflow, lighting, and regulatory needs
• Compressing the concept-to-surface development cycle
• Managing multiple design iterations within a short decision window

The Solution

We leveraged its 24×7 global engineering model and multidisciplinary team to deliver a fast, design-led execution.

Key solution components included:

• Benchmarking and feature matrix creation to align design priorities
• Multiple styling concepts and permutations created for rapid review
• ‘A’ surface definition and integration within the existing structural package
• Concept refinement based on airflow, lighting system, and manufacturability constraints
• Engineering validation of minimal structural changes and tooling impact
• Continuous engagement with client stakeholders for approvals and iteration cycles

The Impact

The newly designed front cap successfully met all styling, technical, and launch expectations:

• Visually distinct exterior achieved with minimal structural changes
• Accelerated design-to-release cycle enabled through global execution model
• Optimized feature integration while preserving airflow and lighting performance
• Successful product launch with enhanced brand appeal and market reception
• Strengthened client confidence in CS Tech Ai’s end-to-end design capability