3D-Printed Recycled Foam Camper Shell Enables 4,500km Expedition

Italian rider Francesco Furlani has completed a 4,500-kilometre road trip from Italy to Nordkapp in Norway behind the wheel of a three-wheeled Piaggio Ape TM 703 equipped with a custom 3D-printed camper body. The lightweight printed shell weighed approximately 70 kilograms, compared to roughly 200 kilograms for a standard fiberglass structure. On a low-power, payload-constrained platform like the Ape, saving 130 kilograms was crucial to making the long-distance trek feasible while carrying essential camping gear, tools, and supplies.

Engineering a Lightweight Thermoplastic Foam Shell

The camper shell was produced using an additive manufacturing approach developed by Italian startup Nugae, termed Ultra-Light Large Format Additive Manufacturing (UL-LFAM). The structure was printed on a NU-Print Large machine using CoreLight3D, a proprietary thermoplastic foam formulated from recycled polypropylene specifically for robotic extrusion systems.

In raw pellet form, CoreLight3D has a density of around 300 kilograms per cubic metre. When extruded into thin-walled structural geometries, the finished component’s effective density drops to roughly 100 kilograms per cubic metre. Using Nugae’s NU-Slice software and a six-axis industrial robot, print paths deposited material exclusively along primary load-bearing vectors rather than filling the structure uniformly. To ensure proper weatherproofing, structural rigidity, and durability without adding excessive mass, specific load-bearing sections of the printed core were laminated with fiberglass or carbon-fibre skins after printing.

Vehicle Integration and Structural Adaptations

Extruding a large lightweight body shell is only half of the engineering equation; mounting it safely to a commercial chassis requires thorough mechanical integration. Italian engineering firm DCab adapted the 3D-printed shell geometry to match the structural layout and mechanical constraints of the Piaggio Ape TM 703 chassis.

DCab designed dedicated mounting points and engineered the overall weight distribution to ensure the printed structure functioned as a load-bearing body cell rather than an unreinforced shell simply bolted to the vehicle frame. The printed parts came off the build volume ready for composite lamination, surface finishing, and assembly, demonstrating how large-format printing can produce practical load-bearing structures for lightweight vehicles.

What This Means for South African Makers

South Africa has a strong culture surrounding custom utility vehicles, off-road trailers, overlanding rigs, and mobile small businesses. While full six-axis robotic LFAM setups remain specialized industrial equipment, the structural principles demonstrated in this build apply directly to local makers and small engineering workshops.

Combining lightweight 3D-printed core structures with composite skins, such as fiberglass or carbon lamination, offers a clear framework for custom camper builds, canopy inserts, and modular vehicle interiors. Utilizing recycled thermoplastics for large structural parts also points to a practical route for low-weight, durable fabrications tailored to local off-grid and utility needs.

DC3D’s Take

This project is a practical demonstration of using additive manufacturing where it makes clear structural sense. Rather than attempting to 3D print a solid plastic enclosure, combining a low-density printed foam core with targeted composite reinforcement solved the strict payload restriction without sacrificing weather resistance or stiffness.

For desktop and prosumer makers, the takeaway is not that you need a multi-axis industrial robot, but that intelligent infill patterns, intentional wall placement, and hybrid material techniques can produce exceptional strength at a fraction of the weight. Designing functional internal skeletons and pairing them with traditional composite materials remains one of the most effective methods for building custom, low-volume structures.