Weight Is the Enemy.
Each ultra-lightweight Leentu camper shell is hand built in Indianapolis, by IndyCar composite component specialists, just miles from the Indianapolis Motor Speedway.
Many objects you encounter in your daily life are constructed with composites-- which for these purposes we loosely define as a fiber to provide tensile strength and some sort of binder to hold it all together. Everything from buses, to hot tubs, truck caps, to boats and aircraft, even your garage floor is technically a composite.
The most common composite construction approach is called a "wet layup" process. This means that layers of fabric are placed in a mold and toxic polyester resin is added until the fabric is saturated. The resin then cures, hardening the whole structure. This results in a product that is strong, but has a large surplus of resin. Unfortunately, the excess resin only adds more weight, it does nothing to strengthen the product.
When we set out to build a better all around truck camper, we at Leentu decided early on in the design process that excess weight and anything that detracts from a vehicles baseline performance must be removed from the equation. To meet this imperative, we turned to aerospace grade composite materials and techniques.
Leentu campers are made with an extremely lightweight rigid core and pre-impregnated composite fabrics using an autoclave process. This is different from commonly utilized cheaper construction methods in that the high grade, epoxy based resin is "dry" and already combined with the fabric in an exact ratio. The layup process is similar in that the fabric is placed in a mold, however, the finished layup is then placed in an air-tight bladder, and the whole assembly is cured in an autoclave (essentially a giant pressure cooker). Within the autoclave, air pressure and heat are used to ensure the best bond possible and a complete cure.
Furthermore, every Leentu camper shell features a "composite sandwich" -- a structure that essentially eliminates the inner layers of a panel (which do little more than occupy space and add weight) -- and replaces them with a rigid honeycomb that is mostly empty space. This is an advanced technique used exclusively in applications such as spacecraft, high performance aircraft, and racecars where light weight, stability and extremely high strength outweigh all other considerations.
All of this culminates in a finished product that is simultaneously the lightest weight, strongest, most stable, least toxic & least wasteful possible with current technology.