How we develop roof racks at Airholder: from OEM 3D data to 3D scanning of the vehicle

A roof rack must fit perfectly from the start: it must sit flush, be easy to install without any tension, and remain stable even after many kilometers. That's precisely why Airholder 's development isn't based on guesswork, but on precise vehicle geometry – either from original 3D design data or from a 3D scan of the actual vehicle .

Here we show step by step how we proceed – and why this approach is ultimately crucial for fit, ease of assembly and reliability.

1) The start: What requirements must the roof rack meet?

We always start by clarifying the general conditions:

• For which vehicle and variant is the roof rack intended (model, wheelbase, roof shape, equipment)?

• What mounting points are available (standard threaded points, rails, specific mounting points)?

• What are the planned usage scenarios (travel, everyday life, off-road, roof tent, cargo transport)?

• Which accessories will be installed later (awning, solar panel, lights, boxes, brackets)?

Once it is clear what the roof rack should do, the most important step follows: exact geometry data for the roof and mounting areas.

2) Original 3D design data: if the vehicle is available digitally

When a vehicle is available in the form of original 3D data/drawings , this is the best case for clean technical development.

This brings great advantages:

• exact roof contours and correct position of the fixing points

• Construction of components directly "to measure" – without estimation or interpretation.

• Fewer iterations, faster development to series production readiness

• defined gap dimensions and a visually "factory-made" appearance

In short: Using original 3D data, we can develop the roof rack in the same way as is known from professional vehicle and system design – precise, reproducible and easy to assemble .

3) 3D scanning: when original data is not available

Not every vehicle is "digitally available" in the required quality. Sometimes the data is inaccessible, incomplete, or insufficient for the specific application. In these cases, we resort to a reliable alternative: 3D scanning of the actual vehicle .

Example: Defender 110

For the Defender 110, we scanned the vehicle and used this data as the basis for the design of our brackets and the entire mounting geometry. The scan provides a precise digital representation of the relevant areas – especially where forces are later applied and components need to fit securely.

What scanning enables us to do:

• We work with the actual roof geometry , not with assumptions.

• Transitions, curves and details are correctly taken into account.

• The brackets can be designed to fit precisely and be installed cleanly.

4) From geometry to component: how brackets and fastening systems are created

Once the vehicle geometry is determined (from original data or scan), the actual design work begins:

1. Developing brackets/consoles
   They must safely absorb the forces, fit snugly against the vehicle, and create a stable connection to the carrier system.

2. Define the interface to profiles and crossbeams
   This ensures the system remains modular and allows for the sensible integration of accessories later (e.g., awning or solar panel).

3. Digital assembly inspection in CAD
   We check access to screws, assembly paths, tolerances, gap dimensions and possible collisions.

4. Prototype & real fitting
   This reveals whether the digital world fits the real assembly process exactly – and where we may need to make fine adjustments.

5. Optimization for series production
   The goal is a component that can be produced in a stable, repeatable and consistently high-quality manner.

5) Why this approach is particularly important for roof racks

A roof rack experiences everyday life and travel:

• Vibrations and dynamic loads

• Weather, temperature changes and continuous stress

• additional loads due to accessories (e.g. awning, roof tent, boxes)

If the geometry in the mounting area is incorrect, problems quickly arise: stresses, misaligned components, unpleasant noises, difficult assembly, or uneven load distribution. Precise data – whether from original 3D models or scans – is therefore the foundation for a system that functions reliably and stably in the long term .

6) Our philosophy: Engineering work instead of “adapting on site”

Airholder 's goal is clear:

• Brackets and mounting hardware should fit the vehicle – not the other way around.

• Assembly should be understandable, quick, and reproducible.

• The result should appear technically sound – like a well-thought-out system, not like an improvisation.