Case Study: Jerba Campervans

By Sam Gribben
August 12, 2025
11:00 am

Source: Jerba Campervans

Jerba Campervans uses additive manufacturing for bespoke, high-end campervan conversions.

Join us as we delve into the innovative solutions that Jerba Campervans, a company specialising in campervan conversions, launched one of their latest products. In this case study, we showcase how Jerba Campervans leveraged additive manufacturing to produce bespoke components that were seemlessly integrated into their product range. The results were a high-quality, end-use solution built to last.

Source: Jerba Campervans

The Challenge: Custom, High-End Components Without the Mould Tooling

Jerba Campervans specialises in converting VW vans into bespoke high-quality campervans tailored to the needs of individual customers. With a strong focus on craftsmanship, safety and detail, their builds require interior components that not only look premium but also perform like production-grade parts.

However, sourcing low-volume high-quality components has been a persistent challenge. Traditional plastic manufacturing methods like injection moulding offer the surface finish and strength they need – but come with high tooling costs and long lead times that don’t align with their flexible low-volume production model.

Jerba needed a solution that could bridge the gap – something fast, adaptable and capable of delivering the same visual and tactile quality as moulded parts without the commitment of mass production.

Source: Jerba Campervans

The Solution: Scalable Low-Volume Production Without Compromise

After closely reviewing the challenge, Jerba Campervans turned to additive manufacturing as a way to produce the bespoke interior components they needed. Their design team developed early-stage prototypes in-house to explore functionality and fit before partnering with SGD 3D to move into production. They selected our Nylon PA12 GF (SLS) for its strength, consistent accuracy and smooth surface finish – ideal for creating robust parts that matched the aesthetic and performance of moulded components. This approach allowed Jerba Campervans to design modular parts with interchangeable sections that could be quickly adapted for different van layouts. The smooth finish also helped reduce friction in moving assemblies, ensuring reliable performance without adding complexity or mechanical systems.

Source: Jerba Campervans

Why Vapour Smoothing?

For Jerba Campervans, the finish and feel of each component is just as important as its function. While SLS printing provided the mechanical performance and design freedom they needed, the natural surface texture of raw nylon wasn’t suitable for visible interior parts.

Vapour smoothing was chosen to elevate the look and usability of these components. The process uses a controlled chemical vapour to gently melt the outer surface of each part, sealing porous areas and creating a uniform semi-gloss finish. This results in a smoother, moulded-like appearance that fits seamlessly into Jerba’s high-spec interiors.

Visual Comparison:

Before Vapour Smoothing: Matte, slightly rough surface typical of raw SLS prints
After Vapour Smoothing: Smooth, satin finish that looks injection moulded

Functional Benefits:

Reduced friction: Ideal for sliding parts or moving assemblies
Easier to clean: Non-porous surface repels dirt and moisture
Improved strength: Surface sealing helps improve part durability and longevity

By combining the strength and accuracy of SLS with the refined finish of vapour smoothing, Jerba achieved production-quality parts without the time or cost of tooling.

Interested in Vapour Smoothing? Read our review on the AMT PostPro SFX machine here

Job Information

Corner End Profile	Low Volume Manufacturing
Technology	Selective Laser Sintering (SLS)
Material	Nylon PA12 GF (Glass Filled)
Finish	Vapour Smoothed (PostPro Pure)
Quantity	100
Lead Time	10 Working Days

Conclusion

Jerba Campervans found that Selective Laser Sintering (SLS) 3D printing technology was the key to producing reliable and effective end cap parts. Their team were able to design a functional, precise and stiff end corner piece that met all the required specifications and suited their end product requirements. This project demonstrates the power of 3D printing technology in solving complex engineering challenges and improving production processes.

Click here to read our materials guide to find out more about the materials we use to print at SGD 3D

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