Challenges
The DN5 suspension system has served FSC Off Road customers successfully for many years. With the growing popularity of hybrid caravans and the evolving demands of off-road use, FSC sought independent verification to ensure the system continued to perform reliably under modern, high-load touring conditions.
Key focus areas included:
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Confirming compliance with VSB14 load cases (rut, skid, and vertical bump)
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Assessing local stress concentrations at the shock absorber and airbag mount regions
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Evaluating options for targeted reinforcement to support higher load ratings without unnecessary weight increases
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Maintaining compatibility with existing suspension geometry and manufacturing processes
Solution
Quantech Design performed a series of finite element analyses (FEA) on the suspension assembly to validate its performance envelope and identify areas where minor structural enhancements could improve fatigue life and load capacity.
This process involved:
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Applying the relevant VSB14 load cases to the 3D suspension model
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Reviewing results for stress distribution and compliance with engineering safety factors
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Recommending localised stiffening and improved material utilisation to enhance robustness
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Confirming that all geometry, mounting interfaces, and overall configuration remained unchanged
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Ensuring the system continued to meet FSC’s manufacturing and assembly requirements
Results
The analysis confirmed that the DN5 suspension system provides strong performance across all test cases.
Through the addition of discreet structural stiffeners and refinement of certain fabrication details, the design now delivers:
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Improved durability and load margin for heavier configurations
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Enhanced long-term reliability under demanding off-road conditions
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Verified compliance with all relevant VSB14 structural requirements
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No change to geometry, clearances, or established FSC manufacturing methods
The collaboration between FSC Off Road and Quantech Design demonstrates a commitment to continuous product improvement and technical assurance. The verified design enhancements ensure FSC’s DN5 suspension remains a benchmark in reliability and performance within the Australian hybrid caravan market.
FSC Off Road is a boutique Australian manufacturer of hybrid off-road caravans. Based in Jindera, NSW, they design and build the DN5 hybrid in-house, focusing on rugged, lightweight, off-grid capability for Australian conditions. Their story is rooted in decades of hands-on outback travel and iterative prototyping, culminating in a purpose-built manufacturing facility for the DN5. The brand’s ethos, “Do it right or don’t do it,” underpins their engineering-led approach, backed by a 5-year suspension and chassis warranty.
