Our luxury truck campers are proudly built using premium 1.5-inch PET composite panels, which are manufactured entirely in the USA. This advanced, closed-cell foam core material delivers an exceptional strength-to-weight ratio, superior thermal insulation, and outstanding resistance to moisture, rot, mold, and delamination – ensuring your camper remains lightweight yet incredibly rigid and durable for a lifetime of adventures. Unlike traditional wood-based composites that can absorb water and degrade over time, American-made PET composite is 100% waterproof, chemically inert, and fully recyclable, providing unmatched longevity and peace of mind in the harshest conditions. By choosing domestically produced, aerospace-grade PET panels, we support American manufacturing while delivering the highest possible quality, precision engineering, and structural integrity that discerning overland enthusiasts demand in a true high-end custom build.

One of the most common questions we receive from prospective customers is, “What makes your panels different?” While many of you have already researched the wide variation in “composite” construction, we’re always happy to explain why material choices matter and why we refuse to compromise on quality to reduce cost.

Our panels and aluminum extrusions are engineered to deliver the strongest, most thermally efficient system available for overland campers. We use a proprietary two-piece aluminum extrusion design that completely eliminates thermal bridging and thermal expansion. The integrated dual glue channels ensure the adhesive remains exactly where it belongs throughout the panel's life; this is a frequent failure point in single-piece extrusion designs, where adhesive can be squeezed out during assembly, compromising bond strength and creating potential leak paths.

Transparency about materials is central to our philosophy. Not all composite panels are created equal, and we want customers to understand exactly what they’re investing in. This article is the first in a short series; today, we’ll focus exclusively on the foam core. Future installments will cover exterior skins, lamination methods, and additional performance details.

The Heart of the Panel: Foam Core Comparison

Many composite camper manufacturers utilize expanded polystyrene (EPS), commonly referred to as Styrofoam. We use structural PET (polyethylene terephthalate) foam core made from 100 % recycled material; the same high-performance foam trusted in wind-turbine blades and premium marine construction.

Density is the single most important indicator of a foam core’s structural capability and is measured in pounds per cubic foot (PCF).

• Standard EPS cores in the camper industry: 2–3 PCF

• Our PET structural foam core: 5 PCF

Higher density translates directly into superior compressive and shear strength, as well as dramatically improved rigidity. A 5 PCF PET core delivers structural performance that an EPS panel would need more than double the thickness to approach; adding that much thickness increases weight and sacrifices valuable interior space.

For a vehicle that will endure repeated off-road punishment, core strength is arguably the most critical specification. The higher density and closed-cell structure of our PET core produce exceptionally stiff panels. Customers are often surprised to learn that our 1.5-inch-thick roof and cabover sections easily support the weight of an adult walking across them with minimal deflection.

In short, the foam core is the foundation of any composite panel. A weak or low-density core limits the performance of even the best skins and bonding processes. By selecting a 5 PCF recycled PET core, we create a panel that is lighter, stronger, and more durable than thicker EPS-based alternatives.