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Smart Modular Electric RVs aren’t just a lifestyle trend — they’re a compact case study in systems engineering, cost control, and manufacturability. Grounded’s latest G3 platform showcases how modular cabinetry, a 48-volt house system, and a software layer can turn a delivery van into either an RV or a revenue-generating mobile clinic. As Munro & Associates highlights through its teardown and lean design work, these vehicles reveal actionable lessons that engineers and product leaders can apply across the EV sector.
From G1 to G3: Iterate fast, standardize smart
Grounded advanced from a prototype-like G1 to today’s G3 in roughly three years. The team leaned on CNC-cut 2D parts to accelerate cycles — shifting CAD to cut parts quickly without committing to hard tooling. That choice preserves agility; it also avoids the sunk-cost trap that freezes designs too early. For low-to-mid volumes with evolving requirements, CNC plus modular subassemblies is a rational cost strategy; unit labor remains manageable while engineering changes land in days, not quarters.
Platform agnostic, customer specific
Instead of clean-sheet vehicles, Grounded builds “experiences on wheels” atop major OEM chassis — notably GM’s BrightDrop Zevo 400/600 and Ford’s E-Transit — to inherit validated drivetrains, service networks, and parts availability. This reduces homologation risk and warranty exposure; it also keeps field service simple for end customers. Inside the shell, configurability rules: an aluminum “cage” establishes controlled datum points so modules align despite body variation. That internal structure is a quiet hero; it localizes tolerance stack-ups and protects fit-and-finish in final trim.
Modularity that actually manufactures
The interior is organized as menu-driven modules — kitchen blocks, overheads, dinette/bed systems, tall storage, and a shower compartment — placed on a grid the configurator enforces. Modules share attachment interfaces and repeated hole patterns; that repeatability is what turns “custom” into “configurable.” Grounded reports ~20 vehicles built to date with capacity for ~4/month; at that scale, a limited module catalog balances variety with procurement sanity. Over time, law-of-large-numbers effects should concentrate demand on winning modules; those can justify selective hard tooling for further cost downs.
Materials: remove touches, remove cost
Traditional RV sandwich panels demand edge-capping and water protection — classic “multi-touch” waste. Grounded chased “honest” materials that come off the CNC effectively finished. Two standouts: (1) a wood-look, rot-resistant composite with higher stiffness than plywood; and (2) decorative, recycled sheet goods (e.g., from appliance plastics and nets) that present a clean cut edge. Each part that avoids secondary finishing removes minutes; each removed minute removes cost. Multiply that across dozens of fronts, partitions, and drawer faces; the margin delta becomes real.
Aerospace-inspired cabinetry: tube frames, light faces
Instead of wood boxes, cabinetry uses aluminum tube frames with composite facings. Benefits stack quickly: higher durability, moisture immunity, lower mass, and simpler field service. Hardware choices also reflect a teardown mindset. Omit protruding handles that snag clothing; use powerful magnets and tolerant soft-close rails rather than fragile plastic latches. The result cuts part count and failure modes; it also speeds install because rails forgive small misalignments. In a moving vehicle, fewer fasteners that can loosen — and fewer parts to rattle — is a reliability win.
Re-engineering the rear: doors, headroom, and insulation
Delivery vans often ship with roll-up rear doors. That feature is useful for parcels; it’s terrible for an RV or clinic. Grounded deletes the roll-up, installs a swing door with two inches of foam, adds glazing as needed, and recovers ceiling height that the roll mechanism previously stole. The change improves thermal performance, acoustics, and packaging flexibility for upper cabinets and a raisable bed. It’s a classic example of redesigning to the actual use case — not the donor vehicle’s legacy mission.
Power architecture: 48 V house, high-power off-boarding
The chassis battery drives the vehicle; a separate 48-volt house pack (10 kWh baseline, expandable) runs the interior: induction cooktop, hot water, water pumps, Starlink, HVAC auxiliaries, and a powered bed. Solar contributes ~1 kW on the roof. Crucially, Grounded communicates with the vehicle to off-board energy: ~3 kW on current BrightDrop models; up to ~7.2 kW on 2026 model-year vehicles with native power export. That unlocks long off-grid stints for customers who can trade range for uptime; a software dashboard and app manage draws, SOC, and runtime estimates so operators can plan workdays or campouts with fewer surprises.
Software matters: configurator to fleet dashboard
A browser-based configurator lets RV buyers pick modules, finishes, and layouts in minutes; on the back end, that selection can auto-assemble the relevant CAD, update the BOM, and stage cut files. On the commercial side, a telematics layer reports health, location, and energy use, while remote controls switch loads as needed. This is what “product is the factory” looks like in practice — rules that constrain choices up front, then ripple cleanly through procurement and fabrication. It’s also what transforms vans into fleets you can actually manage.
Design lessons for engineers and investors
- Design to the datum, not the donor. The aluminum cage creates a controlled interface; it’s the key to repeatable fit in variable shells.
- Catalog first; custom last. Lock module envelopes and interfaces; evolve internals as learning accumulates.
- Delete touches; delete parts. Choose materials that ship “finished” off the CNC; replace latches with magnets; standardize rails; remove handles.
- Tool only the winners. As orders cluster on certain modules, shift those to hard tooling for cycle-time and quality gains.
- Instrument the product. Telematics and a 48-V energy budgeter make workflows predictable — whether cooking in the woods or running a mobile dental compressor all afternoon.
What this means for the EV ecosystem
Grounded’s approach previews how broader EV upfit markets may evolve: donor platforms from big OEMs; configurable interiors with repeatable interfaces; house energy systems that treat traction packs as buffers; and software that ties it together. That’s compelling for mobile healthcare, education, and event marketing — use cases with real operating budgets. It also hints at where costs fall next. As volume concentrates on a finite module set, suppliers can pre-assemble submodules; aluminum frames can move to jigs; and composite faces can shift to nested, high-yield cut plans. The result is a virtuous cycle: better quality, lower cost, and faster lead times — without abandoning customer-specific layouts.
Continue with Munro — Go Deeper, Cut Waste, Build Better
At Munro & Associates, we benchmark interiors like these against best-in-class manufacturability, energy architecture, and cost. If you want expert reviews and analysis, module interface rationalization, or an independent costed BOM for your next upfit program, explore Munro reports and subscribe to Munro Live for ongoing engineering breakdowns and lean design reviews.