PROJECTS

Design a 6 m version of an existing 8 m fiberglass trailer without producing a new expensive body mould or changing the established exterior design. The project also required a new chassis, complete kitchen interior, electrical and water systems, while keeping the finished trailer within a 3600 kg gross weight limit

The fiberglass body concept was adapted to manufacture different trailer lengths using the existing 8 m tooling. A new chassis was designed from laser-cut and bent sheet metal, with FEA used for weight optimization. Cabinets, worktables, shelving, extraction, utilities, and other interior components were redesigned for the 6 m layout, with several modules standardized for future models

The same fiberglass tooling was successfully used to produce 8 m, 6 m, and 4 m trailer versions, eliminating the need for separate expensive moulds. The 6 m trailer weighed 1769 kg empty and 2514 kg fully equipped, remaining well below the 3600 kg permitted gross weight. The new bent-sheet chassis reduced assembly time from approximately 6 days to 3 days. Standardized cabinet and worktable designs were later reused across other trailer models, and the 6 m version entered serial production in multiple customer-selected colors

Design a fully custom 6.5 m premium restroom trailer from scratch based on the client’s references and technical requirements. The trailer had to include separate male and female sections, premium interior finishes and utilities, while keeping the total weight below 3500 kg and maintaining correct structural balance

The chassis, body frame, interior layout, plumbing, electrical systems and access solutions were developed as one integrated design. Retractable staircases were designed for both sections, mirror-finished stainless-steel panels were partly bonded with adhesive sealant to avoid visible fasteners, and a custom tarpaulin protection system was developed to protect the exterior during transport and storage

The completed trailer had a full weight of 2,678 kg, remaining 822 kg below the 3,500 kg limit. It included separate male and female sections, hot water via an integrated water heater, lighting and audio systems, premium Grohe and Geberit sanitary equipment, decorative forged-steel ceiling elements, retractable access stairs and a rear photo-zone. The project was completed as a one-off custom unit

Design a 6 m two-zone commercial trailer with a maximum permitted gross weight of 3200 kg, combining a lightweight but rigid body frame with insulated thermal panels. The project also required the complete interior to be engineered from scratch, including cabinets, worktables, storage units, shelving, electrical systems, and onboard water and drainage

A spatial frame made from 50×50×3 mm square tubing was selected as a cost-effective alternative to laser-cut and bent sheet-metal construction. Standard 6 m tube lengths reduced the number of joints and welding operations. The frame layout was optimized through FEA so that panel joints and fastening points aligned directly with the structure. A retractable staircase was also designed into the trailer body, eliminating the need for a separate external step during transport and operation

The completed 6 m trailer weighed 1577 kg against a permitted gross weight of 3200 kg. The project included a fully engineered electrical system, internal water and drainage system with separate 80 L fresh- and 80 L waste-water tanks, and a complete two-zone interior with cabinets, worktables, shelving, storage, and refrigeration areas. The trailer was manufactured, delivered to the client, and immediately put into commercial operation at a festival.

Redesign the original 8 m fiberglass trailer to reduce its total weight from nearly 5000 kg to within the permitted 3600 kg, while preserving the exterior concept and full commercial kitchen functionality. The original frame was also slow to manufacture, requiring about 14 working days due to numerous flat welded parts, extensive positioning, measuring, and dedicated fixtures

The frame was redesigned using laser-cut and bent sheet-metal parts to reduce welding, weight, and assembly time. Steel thicknesses were reduced from 5–6 mm to 3 mm, and to 2 mm where possible, with FEA used to verify strength and stiffness. Key interior components, the retractable staircase, door hinge, drainage, and storage systems were also redesigned and standardized

The redesigned frame was 37.1% lighter, while assembly and welding time was reduced from 14 to 8 working days. The finished empty trailer weighed 1873 kg, leaving substantial payload capacity within the 3600 kg limit. The 8 m model became the base platform for the entire product family: its fiberglass tooling, chassis interfaces, cabinets, doors, worktables, staircase, and other components were later reused in the 6 m and 4 m versions. The model entered serial production, and one unit was later used in a culinary show in Bulgaria

Develop a 5 m Airstream-style food trailer body around an existing customer-supplied chassis. The project required adapting the chassis for the new aluminum body, designing the complete interior equipment, and integrating a serving shelf flush with the exterior body instead of using a conventional protruding counter

The chassis was modified with dedicated slots for floor insulation to reduce heat loss during winter operation. The body was welded from aluminum sheet, while the serving-counter area was redesigned with mineral-wool insulation because of the reduced wall thickness. The structure around the large window and recessed counter was reinforced and checked for sufficient stiffness and strength. The complete interior, including the extraction hood, worktables, cabinet and suspended shelf, was also designed

The project was completed as a custom production run of two units

Redesign an existing churros cart based on a customer-provided sample, incorporating the client’s requested layout changes and allowing installation of a wider fryer while keeping the cart compact and transportable

The cart was rebuilt around a welded steel-tube frame with sheet-metal cladding, a stainless-steel worktop, and a removable upper structure for easier transport and storage

The revised design was prepared for repeat production and moved into small-series manufacturing in batches

Design a 5 m mobile beach bar within a 3,600 kg permitted gross weight, combining a full-service bar area with a separate enclosed sanitary room while maintaining sufficient working space inside the trailer

The chassis, body structure, thermal-panel layout and internal zoning were designed as one system. Large service openings were integrated into the side walls, while the rear section was separated into an independent sanitary room. Insulated thermal panels were used for the body to combine exterior cladding and thermal insulation in a single construction

The 5 m design became a standardized platform used not only for mobile bars, but also for retail kiosks on wheels. The same body and layout concept was adapted for different commercial applications and moved into serial production

Design a fiberglass commercial trailer with a maximum gross vehicle weight of 1800 kg, while integrating the complete interior equipment package, including stainless-steel cabinets, worktables, a suspended shelf, and an extraction hood

Completely redesigned the chassis frame and supporting body structure, replacing many welded assemblies with bent sheet-metal components. The interior layout and equipment were also designed from scratch, including worktables, cabinets, shelving, and the extraction system, with focus on manufacturability, assembly speed, and weight reduction.

The new frame and body design significantly reduced the number of welded components and simplified production. Chassis frame assembly time was reduced from 5 days to 2 days. FEA was used to verify structural strength and stiffness, allowing unnecessary material to be removed without compromising the required load-bearing performance. Combined with the wider use of optimized bent components, this reduced the frame weight by 11.83% while maintaining structural integrity. Two modifications were developed and implemented