Choosing a RLD Design canopy is choosing a lifestyle of travel and adventure, say the manufacturers.

The coronavirus (COVID-19) pandemic has triggered an unprecedented crisis around the world. One of the hardest hit is the tourism industry, with immediate and immense shock to the sector. However, COVID-19 brought life – and most businesses – to an extraordinary standstill. Shops shuttered, airlines stalled and the immediate halt of travel and tourism brought the broader hospitality industry to its knees. For the industry to survive the immediate fallout of COVID-19 and future crises of its kind, it will need to innovate and integrate e-commerce into their business models.

But what the pandemic did highlight, when our freedom was eventually granted, was that becoming a tourist in your own country almost became an obsession with many. And guess what! South Africa is a very beautiful country and has many and varied attractions to visit – from raw nature to the upmarket, with great distraction and surprises around every corner. And at a price that we can afford.

All South Africans love the outdoors

It is no surprise then that manufacturers of any equipment or accessories related to outdoor adventure will be the ones that will grow in future. With a passion for the outdoors and exploring the new, the restrictions placed on our movement were more than a hinderance. Now that these restrictions have been lifted South Africans have been furiously gearing up and booking their leisure accommodation and activities.

With its diversity of landscapes South Africa lends itself to exploring, feeling and touching, awakening all our senses.

“South Africa is one of the most beautiful tourist destinations in the world. When you see its exquisite beaches, stunning countryside and rugged mountainous backdrops, you can understand why,” said Gräbe de Villiers, CEO of RLD Design.

“South Africa is a country where you can experience it all. From the unspoilt beaches along the Wild Coast to the deserts of the Kgalagadi to the lush, green forests of Tsitsikamma, to the mountains of the Drakensberg, to the unforgettable game viewing in our national parks. One moment you can be cage-diving with Great White sharks, the next you’re enjoying a traditional braai and a bottle of Pinotage along the Garden Route.”

Like everything else hotel, B&B and general accommodation is becoming expensive. Nowadays there are a myriad of options available to fulfil the keen outdoor and off-road traveller’s needs. But there are not many available that allow you to have the versatility of using your vehicle for your leisure adventures and without much inconvenience returning it to the OEM design and use, namely a vehicle

“In short all South Africans love the outdoors but like everything else hotel, B&B and general accommodation is becoming expensive.”

“There has also been an explosion of the mountain bike industry with enthusiasts wanting to explore every corner of our country and those of the neighbouring countries.”

“Coupled with the fact of the cost of caravans and the harrowing experience of towing and housing one, we were confident that we could manufacture a product that would without doubt be worth considering if you’re thinking of buying a product that would be affordable but would also allow you the freedom of realising your off-road dreams, without the cumbersome logistics associated with a caravan or a 4×4 trailer.”

“One that would allow you to travel and sleep at a different setting every night, i.e. overlanding, a market that what we are currently working towards getting more traction in.”

“The company was established in 2014 by Riaan Ludik, an engineer with a passion for the outdoors. Further to the adventure and outdoor life experiences, engineering solutions and customisation was also part of his daily life while he worked for a corporate.”

RLD Design have recently invested in a second press brake – a Bystronic Xpress 160/3100

RLD Design has invested in a Bystronic BySmart 3kW fiber laser with a bed size of 3 000mm by 1 500mm. The machine has reduced most of the bottleneck in the cutting department

“However, after careful self-evaluation Riaan decided to explore his passion for design in the leisure equipment market. Most of his ideas were born from real life requirements and the need to have workable solutions to ease the tasks and adventures at hand. Through innovative and practical thinking, Riaan designed and manufactured a range of cost effective, quality engineered products.”
Canopies
“Nowadays there are a myriad of options available to fulfil the keen outdoor and off-road traveller’s needs. But there are not many available that allow you to have the versatility of using your vehicle for your leisure adventures and without much inconvenience returning it to the OEM design and use, namely a vehicle.”

“With cost, aesthetics and quality as the driving forces Riaan designed a range of canopies that can fit all OEM manufactured bakkies in South Africa.”

Stainless steel canopy considerations
“Canopies come in a variety of shapes and sizes and are constructed using different materials, with your budget typically dictating what path you’ll head down when the time comes to swipe the credit card. Typically, you’ll have to choose between stainless steel, fibreglass, aluminium or a form of plastic construction.”

“The material we process ranges between 1.2mm and 1.5mm and certain specials require 2mm. As a result we were not looking for powerful but rather for speed, versatility and quality of cut when we decided to invest in a fiber laser.”

The process to manufacture a canopy, which takes five days, involves laser cutting, bending, welding, powder coating and assembly. RLD Design keeps costs down by using an associated powder coating company that is located in the same facility

“The new breed of canopies are made from stainless steel or aluminium and offer greater roof load-carrying capabilities, sturdier construction and extra durability. Most fibreglass canopies can only carry a load of 50 to 70kg without some sort of additional internal frame. Most metal canopies are rated for 300kg-plus load carrying capacity and weigh about the same as conventional fiberglass canopies.”

“Riaan opted for stainless steel because it is an extremely strong and versatile material and, contrary to popular belief, it isn’t as heavy as you’d think. Due to the strength of the stainless steel the canopy can be manufactured from much thinner gauge, and it is therefore lighter, without sacrificing strength. As an example, RLD Design’s stainless steel canopies have a starting weight of 75kg up to 95kg, which is almost negligible when compared to a vehicle’s carrying capacity of at least 750kg.”

“A secondary benefit, like aluminium, is that due to the rigidity of stainless steel, you can have much larger door openings, making it significantly easier to access your equipment in the back. However, you must keep in mind that metal fatigue is more prominent in aluminium than stainless steel, so aluminium may have a tendency to crack more easily over time.”

“Whether you’re buying a canopy for your bakkie in South Africa, a tub topper, as they refer to it in Australia or you want to turn the bed of your truck into a fully welded stainless steel vault for work or play, as they refer to it in the USA and alternatively called a truck cap, a canopy is an effective and popular way to keep tools, camping and off-road equipment securely stowed, sorted and protected, from both the weather and prying eyes. They also provide a great base to attach other accessories such as racks and rooftop tents, as well as for the installation of electrical systems and storage drawers.”

In the bending department RLD Design have a Durma AD-R30100 press brake operating

With the new cutting and bending equipment a bottleneck has now been created in the welding department. Currently RLD Design are doing research on automating this department and are working with automation partners to provide robotic and motion-based solutions amongst others

“The budget-friendly price tag is a big drawcard but you must compare apples with apples. Material used, coating finish (powder coated or not). Do you have to assemble the product yourself before you can fit it? Would you be able to replace components easily? Fitment – does the product bolt on to the OEM mounting hooks in the load-bin? Lead time to obtain the product and, most importantly, aesthetics … does the canopy complement the bakkie and add value?”

“Don’t go for the cheapest option and also don’t buy something simply because of its name. Make sure about the value for money and also the expandable accessories that could be fitted after fitment or as your need to expand arises.”

“Due to the unique materials and design of the canopy, there are endless customisation opportunities inside and out. For example, we can custom mount just about any rack on the market to the top of the canopy. You can then fit a BunduTec, one of the accessory suppliers that we deal with, 30-second electric rooftop tent.”

“Options include removable roof tops, bed drawer systems, bed cargo slides, drop-down table holders, integrated roof racks, step ladders, bench seating, fold out arm rests, ammo crate sliders, bin sliders, load bars and lots of different window and side hatch configurations. The most talked about option is the fully stocked kitchen side cabinet. It fits all the cooking and serving utensils you’ll need on your next adventure, along with a few bottles of adult beverages.”

“Our kitchen units are available in 4-piece or 6-piece options. The drop-down table completes the kitchen unit. A kitchen cavity and foam insert is also available if you prefer to add your own cutlery.”

“Our units are mainly manufactured for lifestyle options such as camping and outdoor adventure. This includes the rooftop tents and additional expandable awning cover.”

Thinking outside the canopy
“We are now expanding into other markets other than just South Africa and the canopy market. We are very well represented and marketed in Australia, a similar country to South Africa, and have had a presence in the US for nearly two years now. This exposure is going to be further strengthened with Riaan moving to the US with his family.”

Stainless steel canopies being assembled

Options to be fitted include removable roof tops, bed drawer systems, bed cargo slides, drop-down table holders, integrated roof racks, step ladders, bench seating, fold out arm rests, ammo crate sliders, bin sliders, load bars and lots of different window and side hatch configurations

“Additionally, we have moved out of our traditional market and have recently designed, patented and manufactured a hunter canopy. This canopy is ideal for hunters and game viewers alike, in that it has a removable roof and three foldout removable benches. The newly launched Gen 3 RLD Stainless Steel Hunter Canopy comes standard with bonded recessed windows and Integrated concealed hinges.”

Manufacturing and equipment expansion
RLD Design has had a relatively fast but modest growth expansion since inception but as their efforts to build the brand are relentless, expansion and acceptance are going to grow.

“Besides the various materials that a canopy can be manufactured from there are numerous manufacturers of canopies for the bakkie or panel van market, and not just for the lifestyle market.”

“Nothing documented but we estimate that out of the approximate 6 000 bakkies sold every month 2 000 are fitted with some sort of canopy, depending on the owner’s requirements. Of this number we believe there are in the region of between 600 and 700 that are manufactured in metal, per month.”

Components that have been cut and bent

Operations Manager Eugene Janse van Rensburg and Gräbe de Villiers, CEO of RLD Design

“We are obviously now part of these numbers and with our growth forecasts we want to be at least at the 250 per month mark by the end of 2021, with 50% of that number being exported to Australia and the USA. This has necessitated a ramp up in production and manufacturing capabilities, keeping as much of the processing inhouse.”

“The process to manufacture a canopy, which takes five days, involves laser cutting, bending, welding, powder coating and assembly.”

New Bystronic fiber laser and press brake
“We have had a plasma cutter doing the cutting of our stainless but it has reached its sell-by-date because of quality, production time and capabilities. In the bending department we have a Durma AD-R30100 operating.”

Crate and bin sliders are examples of options that can be fitted and are also manufactured by RLD Design

“The material we process ranges between 1.2mm and 1.5mm and certain specials require 2mm. As a result we were not looking for powerful but rather for speed, versatility and quality of cut when we decided to invest in a fiber laser. The Bystronic BySmart 3kW fiber laser with a bed size of 3 000mm by 1 500mm was what we decided on and the machine was installed in July this year.”

“The machine has certainly got rid of the bottleneck in the cutting department but it created one in the bending department and this is why we have invested in a second press brake – a Bystronic Xpress 160/3100.”

“To give you an idea of the productivity gains in cutting, what could conventionally be done in one week on the plasma cutter, is now done in one day using the fiber laser, way above our expectations but rewarding because of the capacity that we now have available.”

Welding automation
“We now have now created a bottleneck in the welding department. Currently we are doing our research on automating this department and are working with automation partners to provide robotic and motion-based solutions amongst others.”

The most talked about option is the fully stocked kitchen side cabinet. It fits all the cooking and serving utensils you’ll need on your next adventure, along with a few bottles of adult beverages

“The powder coating facility also has extra capacity so as we get more established in South Africa, Australia and the USA, we will be able to increase our numbers as we will have the capacity. The only bottleneck going forward that I see will be factory space. A nice problem to have.”

“RLD Design canopies are made entirely of stainless steel and can withstand any overland or work situation you can throw at them. Designed and made in South Africa using SolidWorks, they’re built with modern methods and materials to make the ultimate products for modern adventure or work vehicles. All components are laser cut and multi-axis CNC bent to 3D CAD models, TIG-welded to ensure quality, and finished off with a heavy, textured powder coat for long-lasting, rugged durability.”

“Interestingly the mix of OEMs that we have at the moment is 50% Toyota Hilux, 30% Ford Ranger and 10% VW Amarok but this changes regularly. We cater for the whole OEM market, however.”

“Looking forward we have plans but they can wait until we have bedded down our export vision. There is also scope for us to increase our penetration locally. The pandemic is helping with South Africans being forced to travel locally but like in the USA we do believe that there is a swing away from the sedan to a bakkie because of the versatility of the vehicle.”

Due to the unique materials and design of the canopy, there are endless customisation opportunities inside and out. For example, RLD Design can custom mount just about any rack on the market to the top of the canopy. You can then fit a BunduTec, one of the accessory suppliers that they deal with, 30-second electric rooftop tent

“There is still a market for the SUVs that never see a dirt road but most South Africans want to get into the countryside with a vehicle that gives them the capabilities and can be equipped to make them feel comfortable. Our ‘bolt in, bolt out’ option of canopy and accessories certainly contributes to their enjoyment and adventure.”

For further details visit RLD Design on www.rlddesign.co.za or www.rlddesignusa.com or www.rlddesign.com.au