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Custom Solutions for Specialty Vehicles

Complex assemblies and components for special-purpose, commercial and emergency vehicles from a single source

Fewer interfaces. Faster implementation.

VELA combines technical responsibility, coordination and implementation for its vehicle project

Concept & Package

  • Technical concepts for assemblies & vehicle systems
     

  • Space, load & integration analyses
     

  • Packaging & functional system architecture

Development & Design

  • Development of complex assemblies & vehicle structures
     

  • Chassis, exterior & system integration
     

  • FEM simulation & functional validation

Prototype construction & validation

  • Functional prototypes & technical demonstrators
     

  • Testing, stress tests & validation
     

  • Integration of technical subsystems

Industrialization & Small Series Production

  • Eligible small series systems & complete vehicles
     

  • Production preparation & quality assurance
     

  • Pre-series production implementation & vehicle integration

Certified data security and process quality:

GTÜ Siegel Certification ISO-9001-2015_e

Body & Chassis

Highly durable. Less weight.

Development, manufacturing, and assembly of highly durable structural and chassis assemblies for special-purpose, commercial, and emergency vehicles.

  • Chassis kinematics & axle systems

  • Lightweight & multi-material structures

  • FEM-based load validation

Lightweight engineering

Carbon monocoque & spaceframe frame

Chassis

Pushrod suspension for maximum driving dynamics

TOTAL VEHICLE

Development & Project Coordination

SMALL SERIES

Prototype & Series Preparation

BENEFITS FOR YOUR APPLICATION

  • Higher payload through reduced system weights

  • Robust structures for real-world operating conditions

  • Optimized driving dynamics and durability

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commercial vehicle platform chassis concept CAD.png

Body & Chassis

Exterior.jpg

Exterior & Trim

interior.png

Interior

Drive.png

Drive & E/E

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Attachments

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System integration

Our special vehicle solutions in use

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Use Case 01: Lightweight Heavy-Duty Axle

Higher Payload.
Greater Profitability.

Challenge

Conventional commercial vehicle axles increase vehicle weight and quickly reach their limits in terms of ride comfort, driving stability and payload when operating under varying load conditions.

​

Solution

Development of a modular lightweight heavy-duty axle for special and commercial vehicles, manufactured from high-strength steels – optionally with air suspension and customized adaptation of track width, wheel sizes and vehicle interfaces to meet specific customer requirements.

​

Result

Up to 15% lower curb weight and 10% higher payload – combined with improved ride comfort and a cost-effective implementation from prototype to series production.

Lightweight construction

Carbon monocoque & spaceframe frame

Chassis

Pushrod suspension for maximum driving dynamics

TOTAL VEHICLE

Development & Project Coordination

SMALL SERIES

Prototype & Series Preparation

Economical from Low Volumes
Tool-efficient manufacturing.

Maximum Ride Comfort
Optional air suspension with self-leveling.

Tailored to Your Vehicle
Customized vehicle integration.

Use Case 02: Special Roof Structure

Complex custom solution.
One contact person.

Challenge

Complex special vehicle solutions require a high level of coordination between development, suppliers, integration and vehicle manufacturers.
 

Solution

Development and delivery of functionally integrated roof and superstructure modules as a ready-to-assemble system solution including design, integration and technical validation.
 

Result

Reduced integration effort, no supplier coordination and faster vehicle implementation without additional internal development capacity.

Lightweight construction

Carbon monocoque & spaceframe frame

Chassis

Pushrod suspension for maximum driving dynamics

TOTAL VEHICLE

Development & Project Coordination

SMALL SERIES

Prototype & Series Preparation

Camper with GFRP roof structure.png

only one technical contact person for the entire solution

Approval- and integration-ready system solution

Relief of internal resources & capacities

Use Case 03: Integrated Vehicle Solutions

From the assembly to the complete vehicle

Challenge

Innovative vehicle concepts require fast development cycles, functioning system integration, and realistic validation.
 

Solution

Technical implementation of complex vehicle projects from development and assembly through system integration to the ready-to-drive complete vehicle prototype.
 

Result

Faster development cycles, reduced interfaces and a fully validated vehicle from a single source.

Lightweight construction

Carbon monocoque & spaceframe frame

chassis

Pushrod suspension for maximum driving dynamics

TOTAL VEHICLE

Development & Project Coordination

SMALL SERIES

Prototype & Series Preparation

Roadready prototypes

Validated complete systems

Rapid development cycles

TECHNICAL QUESTIONS. CONCRETE ANSWERS.

  • Special-purpose vehicles are developed wherever standard production vehicles reach their technical or functional limits. Depending on the application, requirements for chassis, body, weight, integration, and certification vary considerably. A development partner should therefore be proficient in both different vehicle platforms and industry-specific requirements.

    VELA develops components, assemblies and vehicle systems for, among others:

    • Special and municipal vehicles

    • Emergency and rescue vehicles

    • Caravans and leisure vehicles

    • Defense and security vehicles

    • Commercial vehicles and special bodies

    • Technology and test vehicles

    • Prototype and validation vehicles

    The focus is on technically and economically optimized system solutions that can be efficiently integrated into existing or new vehicle platforms.

  • Legal, technical, and vehicle-specific requirements should be considered during the development phase. This helps avoid later adjustments and allows for efficient preparation of approval processes.

    ​

    Depending on the project scope, this includes, among other things:

    • UN/ECE regulations

    • EU type approvals

    • Road Traffic Licensing Regulations (StVZO) requirements

    • EMC and electrical safety requirements

    • Axle load, center of gravity and weight specifications

    • Bodybuilder guidelines

    • OEM specifications

    • Requirements for lighting, signaling systems and vehicle bodies

    Topics such as:

    • High-voltage integration

    • thermal protection

    • Add-on parts & interfaces

    • Structural and long-term durability

    • Packaging & Installation Space

    are integrated into the development process at an early stage.

    VELA takes these requirements into account in early development phases and develops integration- and certification-ready vehicle solutions with high technical feasibility and reduced project risk.

  • Technical integration determines whether individual components will later work together as a functioning overall system. Mechanical, electrical, and functional interfaces should therefore be coordinated during the development phase.

    Typical integration tasks include:

    • Structural and exterior modules

    • Thermal management systems

    • electrical and electronic systems

    • Attachments and functional modules

    • Interior and control assemblies

    The focus is on:

    • reduced interface complexity

    • coordinated overall systems

    • ready-to-assemble modules

    • technically validated vehicle solutions

    VELA develops integrated vehicle solutions, reduces interfaces and delivers technically coordinated, ready-to-assemble modules and systems.

  • Yes. Especially with new vehicle concepts, prototypes enable technical validation, testing, and testing before series production begins. Crucially, this requires a partner who can handle development, assembly, and system integration from a single source.

    The scope of services includes, among other things:

    • Concept development

    • Design & Simulation

    • Prototype construction and assembly

    • System integration

    • technical safeguards

    • Testing and validation

    Depending on the project scope, the following may occur:

    • Technology demonstrator

    • Validation vehicles

    • Demonstrator vehicles

    • functional prototypes

    • near-production vehicle concepts

    This allows complex vehicle solutions to be tested and validated realistically at an early stage.

  • Standard chassis systems quickly reach their technical limits, especially in special-purpose, commercial, and emergency vehicles. Customized solutions allow for optimal adaptation to the vehicle concept, operating profile, and economic requirements.

    ​

    Typical use cases include:

    • high payloads

    • changed focus areas

    • Special superstructures and roof systems

    • Off-road or continuous use

    • special vehicle dimensions

    • Lightweight construction and packaging requirements

    ​

    In such cases, a custom-designed chassis or axle solution can offer significant advantages .

    VELA develops:

    • heavy-duty special chassis

    • Lightweight axle systems

    • Multi-material structures

    • Integration-capable chassis modules

    • vehicle-specific kinematic and structural concepts

    This will include:

    • Axle loads

    • Key locations

    • Spring and damper characteristics

    • Durability

    • Construction space

    • Weight

    • Driving dynamics

    • Integration effort

    simulated and optimized at an early stage.

    Depending on the vehicle concept:

    • Reduce empty weights by up to 15%

    • Increase payloads by up to 18%

    • Reduce operating costs and energy consumption

    Especially with specialized vehicle platforms or complex superstructures, individual chassis solutions are often more economical and efficient than off-the-shelf systems.

  • Yes. VELA develops ready-to-assemble roof, body and exterior modules for caravans, commercial vehicles and special vehicles.

    This includes:

    • Design & Lightweight Development

    • Deep-drawn and GRP components

    • integrated structural and functional modules

    • technical system integration

    • production-ready implementation

    • Development relevant to regulatory approval

    Customers benefit in particular from:

    • only one technical contact person

    • Complete solutions capable of integration

    • reduced coordination effort

    • lower internal resource commitment

  • The choice of the appropriate manufacturing process significantly influences tooling costs, component costs, and the economic viability of a project. Therefore, it should be examined as early as the concept phase which process offers the best solution in terms of quantity, component geometry, and technical requirements.

    ​

    Key selection criteria include:

    • Quantities

    • Tooling costs

    • Level of integration

    • Weight & structural load

    • Surface requirements

    • UV and temperature resistance

    • Repairability

    • Assembly and system costs

    Typical manufacturing processes compared

    Proceedings

    GRP hand laminate

    RTM / Infusion

    Deep drawing

    SMC / Pressing process

    Carbon composite

    Typical quantities

    1–50 pieces

    50–500 pieces

    100–5,000 pieces

    >1,000 pieces

    Prototype / Small series

    Tooling costs
    small amount

    medium

    medium

    high

    medium-high

    Example: Wind deflector / roof module

    Proceedings

    GRP hand laminate

    Deep-drawn ABS

    RTM Composite

    Tooling costs*
    €2,000–10,000

    €8,000–35,000

    €15,000–€60,000

    Fewer interfaces mean more control, faster decisions, and more stable projects.
    All process steps are integrated and coordinated from an early stage.

    • Shorter communication and coordination channels

    • Fewer iterations and later changes

    • Greater predictability and transparency

    • Faster and more efficient project implementation

    VELA accompanies projects throughout the entire process – from the initial idea to the production-ready solution.

    * Depending on size, geometry, surface area and level of integration.

    The values shown represent typical orders of magnitude and serve as a guide. The most economical solution always depends on component geometry, functionality, surface quality, and the planned production volume.

    ​

    VELA supports customers as early as the concept phase in selecting the optimal manufacturing process and develops economical plastic, thermoformed, composite and fiber composite components – from prototype to series production.

  • Yes. Especially in special vehicle construction, economical solutions for small and medium production runs are crucial.

    VELA develops vehicle and system solutions for :

    • Unique pieces

    • Prototypes

    • Pre-production series

    • Small production runs

    • specialized vehicle platforms

    Already in early development phases :

    • Manufacturing strategy

    • Tool concepts

    • Material selection

    • Supply chain

    • Integration effort

    optimized for the later production volume.

  • VELA develops integration-ready system solutions from a single source – from the assembly to the technically coordinated vehicle module.

    This reduces:

    • Supplier and interface coordination

    • internal development costs

    • Integration risks

    • Voting times

    • technical friction losses

    Customers receive ready-to-assemble and integration-ready solutions with clear technical responsibilities and high implementation quality.

Let us implement your project in a structured manner!

Talk to us about your requirements – we bring your robust special vehicle solution to reality.

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