Buckley Conversions Builds a Luxury Camper Van Interior, 3D Printed Almost From Scratch

Buckley Conversions has turned the camper van world upside down with a new build that replaces almost every interior panel with a 3D-printed part. The result is a Sprinter-based van that weighs roughly 1,500 pounds less than a traditional plywood-and-aluminum conversion, while looking like a premium apartment on wheels.

Founder Brandon Buckley spent 13 years living full time in vans and a decade building conversions before deciding the old methods had reached their limit. Plywood warps, aluminum racks rattle, and custom cabinetry takes weeks to fit. His answer was to scan the van chassis, design every piece in software, and print the interior in large sections using an industrial KUKA robot arm equipped with an extruder.

The prototype is based on the Mercedes-Benz eSprinter with a 144-inch wheelbase. Buckley claims the printed interior alone weighs about 440 pounds once everything is installed. That is a drastic drop from a standard build, and on an electric van the savings go straight into range. The base van still supports Level 2 charging, and the interior includes a 3,000-watt inverter, built-in air conditioning, heated floors, freshwater storage, and a shower.

Visually, the interior is stealthy and dark. There is no exposed wood grain or bright trim. An L-shaped couch dominates the living area, a Murphy bed folds down over it, and the kitchen has moved to the front of the van. The only non-printed materials are the tambour faces, the ceiling, and the countertop. Buckley says the next version will go fully biodegradable with composite materials that can be finished to look like wood, marble, or anything else the buyer wants.

The build process is where things get interesting. Buckley plans to print the entire interior as one continuous piece, then cut out window and door openings, pre-install electronics on benches, and drop the whole assembly into the van with threaded inserts. That is a big shift from fitting cabinets piece by piece in a small space. The company is also working on an online configurator that uses AI to shuffle layouts, colors, and finishes, then sends the chosen design straight to the printer.

Pricing reflects the niche. A 144-inch model starts at $350,000, and the 170-inch version begins at $370,000. A $7,500 deposit holds a spot. Traditional diesel Sprinters will be offered alongside the electric version for buyers who want more range or lower upfront cost. Buckley says lead time after deposit is about six weeks, which is fast for a coach-built vehicle.

Why it matters

This is not a garage experiment. It is a fully engineered production workflow aimed at replacing manual craftsmanship with repeatable manufacturing. If the price comes down and the process scales, 3D-printed interiors could move from luxury novelty to standard option across the van life and RV industry. For now, it is a striking proof of concept that large-format additive manufacturing can build brackets, fittings, and full interior sections.