Zone RV
Zone RV is an Australian manufacturer of luxury off-road caravans based in Coolum Beach, Queensland, producing composite-bodied Expedition, Peregrine, Sojourn, and Summit models for off-road enthusiasts, couples, and families across Australia. Now operating under new ownership after a December 2024 administration, the company combines advanced composite construction with large-format 3D printing for mold and component production.
- Company typePrivate
- Founded2016
- HeadquartersCoolum Beach, Australia
- Headcount51–100
- GTM typeB2C
- OfferingHardware or Manufacturing
What Zone RV does
Zone RV (legal entity Adventure Zone RV Pty Ltd) is an Australian manufacturer of luxury off-road caravans headquartered in Coolum Beach, Queensland, founded in 2016 by Dave Biggar. The company designs and builds five core caravan models—Expedition (hybrid pop-top/hardtop), Peregrine (19ft couples), Sojourn Couples, Sojourn Family (sleeps up to five), and Summit (premium luxury)—alongside a complementary MODE 4x4 composite canopy line. Its core technology differentiator is all-composite body and cabinetry construction drawing on aeronautical and marine industry methods, enabling lightweight yet durable vans that stay within tow-vehicle Gross Combined Mass limits. Zone RV operates the largest 3D printer in the Southern Hemisphere (Virtual Smart Factory VSF122, 22m x 5m x 1.6m build volume, acquired from CNC Design in June 2022 via a $1.16M Made in Queensland grant) inside a $7.5M, 5,000-square-meter Coolum Eco Industrial Park facility used for mold production and composite component manufacturing.
The business model is direct-to-consumer and dealer-mediated one-time unit sales with extensive customization revenue layered on top: BASE models start below AUD $100,000, with optional upgrades (BCS suspension $4,000, Toughcoat Protection Pack $2,950-$5,900, diesel air heater $1,950, washing machine $1,650, Starlink $999, 400-800Ah lithium banks, 720-1,240W solar arrays) materially increasing average selling price. Distribution combines an authorized dealer network across Australia with factory-direct delivery to Sunshine Coast QLD, Sydney NSW, Melbourne VIC, and Perth WA ($5,000 surcharge). Marketing leverages an active Instagram community, YouTube walkthroughs, an Adventures blog, the annual Zone RV Muster, and Mundi Mundi Bash participation to drive awareness and referrals. The customer portal and service network provide after-sales support.
Zone RV entered voluntary administration in December 2024 owing $42M to creditors, with ~140 customers owed more than $10M for undelivered caravans; liquidator Cor Cordis is pursuing a potential $21M insolvent-trading claim against the former director. The business subsequently restarted under new ownership led by Jamie Johnson with Peter Johnson as General Manager, resuming production on a refreshed production line and repositioning under an 'Our Next Chapter' narrative. The company does not publicly disclose revenue and has no AI/ML capabilities evident in the data.
Zone RV firmographics
Firmographics- Name
- Zone RV
- Legal name
- Adventure Zone RV Pty Ltd
- Website
- https://zonerv.com.au
- Company type
- Private
- Founded year
- 2016
- Operating status
- Operating
- Headcount range
- 51–100 employees
- Short description
- Zone RV is an Australian manufacturer of luxury off-road caravans based in Coolum Beach, Queensland, producing composite-bodied Expedition, Peregrine, Sojourn, and Summit models for off-road enthusiasts, couples, and families across Australia. Now operating under new ownership after a December 2024 administration, the company combines advanced composite construction with large-format 3D printing for mold and component production.
- Ownership category
- akta.pro rank
Zone RV industry classification
Industry- Product category
- Off-Road Caravans
- NAICS
- Travel Trailer and Camper Manufacturing (336214)
- SIC
- Truck Trailers (3715)
- akta.pro primary industry
- Recreational Vehicle (RV) Bodies & Towables Manufacturing (IMACAGAJ)
Keywords
Where Zone RV is headquartered
LocationHeadquarters
- HQ city
- Coolum Beach
- HQ country
- Australia
- HQ region
- Oceania
Offices3 records
Markets served
Zone RV business model
Business model- GTM type
- B2C
- Offering type
- Hardware or Manufacturing
- Cost components
- Supply Chain
Revenue model
- Off-road Caravan Sales: Zone RV generates primary revenue from manufacturing and selling Australian-made off-road caravans. Customers purchase vehicles through dealers or factory-direct, with prices starting below AUD 100,000 for BASE models. Additional revenue comes from extensive customization options and accessories.
- Customization and Accessories: Zone RV offers numerous optional upgrades including suspension packages, battery banks (400Ah-800Ah), solar arrays (720W-1,240W), protection packs, and comfort features. These add-ons provide incremental revenue per vehicle.
- Service and Warranty: Zone RV provides 7-day alignment services, 24/7 roadside assistance, warranty claims processing, and ongoing support through its service network and customer portal.
- Government Grants: Zone RV received a $1.16 million Made in Queensland (MiQ) grant, which funded the 3D printing technology acquisition, expanded production capacity, and creation of 99 jobs.
Pricing tiers
| Model | Billing | Price |
|---|---|---|
| Unit Pricing | Pay-as-you-go | BASE Model - Starting price point |
| Unit Pricing | Pay-as-you-go | Peregrine Pioneer Specification |
| Unit Pricing | Pay-as-you-go | Peregrine Summit Specification |
| Unit Pricing | Pay-as-you-go | Optional Upgrades and Add-ons |
| Unit Pricing | Pay-as-you-go | Delivery Surcharges |
Go-to-market motion2 records
Distribution channels6 records
Marketing channels6 records
Zone RV product offering
Product offeringCore offering
Zone RV manufactures and sells Australian-made off-road caravans (Expedition, Peregrine, Sojourn Couples, Sojourn Family, Summit) with all-composite body and cabinetry systems that incorporate aeronautical and marine industry technology. The company uses the largest 3D printer in the Southern Hemisphere for mold production, offers gasless interior designs with lithium battery and solar power systems, and equips its caravans with Cruisemaster airbag suspension for off-road performance. Distribution occurs through an authorized dealer network and factory-direct delivery across Queensland, NSW, Victoria, and Western Australia, with sales driven by an online configurator for customization.
Product overview
Zone RV is an Australian manufacturer of off-road caravans headquartered on the Sunshine Coast, Queensland. The product portfolio consists of five distinct off-road caravan models (Expedition, Peregrine, Sojourn, Sojourn Family, and Summit) and a complementary accessory line (MODE 4x4 Canopy). All caravans feature composite body construction, lithium power systems, solar panels, and CruiseMaster suspension. The company also operates a 3D printing facility using the largest 3D printer in the Southern Hemisphere for mold production. Zone RV provides customer support through service centers, a customer portal, warranty coverage, and a handover experience program.
Differentiator
Problem solved
Functional benefit
Brands
- MODE Canopy: A ute canopy product line manufactured by Zone RV, featuring composite construction, chassis-mounted design, and compatibility with various vehicle models including Volkswagen Amarok and Ford Ranger.
Products and services
- Zone RV Expedition The Zone RV Expedition is a hybrid off-road caravan featuring aggressive rear departure angle, shorter length, pop top roof, full-size queen bed, optional bunks (sleeping up to four), outdoor kitchen, storage compartments, and ensuite with shower. It is available in Poptop or Hardtop configurations.
- Zone RV Peregrine The Zone RV Peregrine is a 19ft off-road caravan designed for couples, featuring full-size queen bed, spacious lounge, air conditioning, luxurious ensuite with separate shower, indoor/outdoor kitchens, built-in washing machine, and Cruisemaster suspension.
- Zone RV Sojourn Couples The Zone RV Sojourn Couples is a 21ft off-road caravan and the roomiest model in the range, ideally suited for extended adventures featuring a couples configuration.
- Zone RV Sojourn Family The Zone RV Sojourn Family is a 21ft off-road caravan delivering comfort, capability, and innovation for families, available with bunks sleeping up to five people.
- Zone RV Summit The Zone RV Summit is the premium luxury off-road caravan crafted for adventurers who demand the best, bringing unparalleled luxury and workmanship with off-road capability.
- MODE 4x4 Canopy The MODE 4x4 Canopy is a composite accessory canopy for utes and trucks, featuring gullwing doors, dust-proof construction, central locking, and various storage solutions. Compatible with vehicles including Volkswagen Amarok and Ford Ranger.
Quantifiable outcome
- Caravans designed to handle Australia's rough terrains and corrugated roads with optimized weight for GCM compliance
- +2 more outcomes
Companies that use Zone RV
Customer profileNamed customers5 records
Segments5 records
Ideal customer profiles4 records
Zone RV technology and API
TechnologyTechnology focussed No
API detail
- Has API
- No
- API docs
- API detail
Core technology
AI maturity
App detail
Integration2 records
Feature6 records
Zone RV partnerships and signals
Strategic signalPartnerships
Three partnerships are on record, tiered core and minor.
- CNC DesigncoreZone RV partnered with CNC Design to acquire the Virtual Smart Factory VSF122, the largest 3D printer in the Southern Hemisphere. CNC Design supplied this large-area gantry-based machine (22m x 5m x 1.6m) that combines five-axis milling with three-axis printing. The partnership enables Zone RV to manufacture composite molds and components for caravan production using cutting-edge additive manufacturing technology.
- Cure MarineminorCure Marine is a sister company to Zone RV, also founded by David Biggar. Zone RV's 3D printing capabilities are shared with Cure Marine for producing catamaran components. Cure Marine used the same 3D printer to create the CURE 55 performance cruising catamaran launched in December 2022, demonstrating cross-industry application of the manufacturing technology.
- CruisemastercoreZone RV partners with Cruisemaster for suspension systems across their caravan range. Models feature Cruisemaster DO35 and DO45 hitches, ATX suspension, and BCS (Body Control System) airbag levelling options. Cruisemaster is a specialized Australian manufacturer of off-road trailer suspension and coupling solutions.
Scale indicators10 records
Recent moves7 records
Expansion highlights6 records
Zone RV competitors and assessment
Company assessmentDirect peers
- Track Trailer: Track Trailer is an established Australian manufacturer of off-road camper trailers with similar remote-area capability focus, comparable independent suspension systems, and overlapping dealer-network distribution strategy.
- Kimberley Kampers: Kimberley Kampers builds Australian-made off-road hybrid caravans using composite/aluminum construction, directly competing with Zone RV's composite-bodied off-road range for the same outback and remote-area touring customers.
- Black Series Campers: Black Series Campers manufactures premium off-road hybrid caravans with comparable aluminum frame and composite panel construction, targeting the same adventurer and family off-grid touring customer as Zone RV.
- Patriot Campers: Patriot Campers manufactures premium off-road camper trailers and caravans in Australia with comparable rugged-construction technology, family and couples configurations, and a similar premium price positioning targeting serious off-road enthusiasts.
- Lotus Caravans: Lotus Caravans is one of Australia's leading premium off-road caravan manufacturers, competing head-to-head with Zone RV in the same luxury off-road segment with comparable composite construction, similar price points (AUD 100K+), and overlapping customer profiles of off-grid adventurers and couples/families.
- Australian Off Road (AOR): AOR builds premium off-road hybrid caravans in Australia targeting the same rugged-terrain adventurer segment as Zone RV, with comparable suspension systems, off-grid power setups, and direct-to-consumer configurator sales.
- Crusader Caravans: Crusader Caravans is an Australian family-owned caravan manufacturer offering off-road capable touring caravans that overlap with Zone RV's Sojourn and Peregrine models for couples and family customers seeking full-feature on and off-road touring.
- Conqueror Australia: Conqueror is a long-established Australian off-road camper trailer manufacturer with similar rugged-terrain durability positioning and dealer network distribution, serving overlapping outback touring customers.
- MDC Campers: MDC builds Australian off-road hybrid camper trailers serving the same couples and adventurer segments as Zone RV, with comparable lightweight construction, off-grid power systems, and online configurator-based direct sales.
Broad incumbents
- Jayco: Jayco is Australia's largest caravan and RV manufacturer offering a broad portfolio from entry-level to premium touring caravans. While not focused on the off-road composite niche like Zone RV, it competes for the same Australian caravan buyers and sets baseline price/reference points in the market.
Market position
Strengths4 records
Weaknesses4 records
Competitive moat4 records
Key risks5 records
Key highlights6 records
Customer concentration
Zone RV social profiles
Digital presenceZone RV financial estimates
Financial estimateRevenue estimate
Valuation estimate
Zone RV leadership team
Management profileNumber of profiles
Profiles2 records
Zone RV funding detail
Funding detailFunding overview
Funding rounds
Investors
Funding detail is available on the Subscription and Enterprise plan.Contact sales →
Zone RV M&A and investment
M&A and investmentM&A
Investments
M&A and investment is available on the Subscription and Enterprise plan.Contact sales →
Frequently asked questions about Zone RV
What does Zone RV do?
Zone RV manufactures and sells Australian-made off-road caravans (Expedition, Peregrine, Sojourn Couples, Sojourn Family, Summit) with all-composite body and cabinetry systems that incorporate aeronautical and marine industry technology. The company uses the largest 3D printer in the Southern Hemisphere for mold production, offers gasless interior designs with lithium battery and solar power systems, and equips its caravans with Cruisemaster airbag suspension for off-road performance. Distribution occurs through an authorized dealer network and factory-direct delivery across Queensland, NSW, Victoria, and Western Australia, with sales driven by an online configurator for customization.
Is Zone RV a public or private company?
Zone RV is a private company. It is classified as founder individual operated bootstrapped and is currently operating.
When was Zone RV founded?
Zone RV was founded in 2016. It employs 51 to 100 people.
Where is Zone RV based?
Zone RV is headquartered in Coolum Beach, Australia, in the Oceania region.
How does Zone RV make money?
Four revenue lines are on record. Off-road Caravan Sales are the primary driver. The others are customization and Accessories, service and Warranty and government Grants.
Who are Zone RV's main competitors?
Direct peers on record are Track Trailer, Kimberley Kampers, Black Series Campers, Patriot Campers, Lotus Caravans, Australian Off Road (AOR), Crusader Caravans, Conqueror Australia and MDC Campers. Jayco is listed as a broad incumbent.
Does Zone RV have an API?
No public API is recorded for Zone RV.
What industry is Zone RV in?
Zone RV's product category is Off-Road Caravans. Its primary akta.pro industry code is IMACAGAJ, Recreational Vehicle (RV) Bodies & Towables Manufacturing. Its NAICS code is 336214 and its SIC code is 3715.