We used fiberglass for hard shell tops. We changed to ABS. It was not a cheap decision – we had fiberglass stock on hand at the time, and ABS tooling costs significantly more than fiberglass tooling. This page explains why we made the change and what it means for anyone buying hard shell tents in volume.
Toughness: the failure mode is the difference
Fiberglass is stiff and strong until it is hit, and then it cracks. The name describes the material: fibre and glass, both brittle. ABS deforms and returns. In a product that travels thousands of kilometres, gets lifted onto roofs by two people and then gets knocked by branches and car park barriers, that difference shows up as damage rates.
It is the same reason vehicle manufacturers moved bumpers from fiberglass to ABS. A bumper has to absorb a low-speed impact and survive it.
Tooling: more upfront, less variance
ABS tooling costs more, and that cost has to be amortised across volume. What you buy with it:
- Dimensional consistency. An injection-moulded shell is the same shell every run. Mounting holes land in the same place, lids seal the same way, and a replacement part fits a unit built a year earlier.
- Less dependence on the operator. Hand-laid fiberglass varies with resin mix, cloth placement and who was on the shift. That variance turns into fitment complaints and into warranty arguments about what “normal” looks like.
- Surface finish out of the tool. Less finishing work per unit.
Freight, claims and what they cost you
A shell that cracks does not just cost a replacement. It costs the freight both ways, the customer’s confidence, and often the distributor’s margin on the whole order. Lower damage rates are worth more than the unit price difference they are measured against.
Where fiberglass still makes sense
Be sceptical of any material claim that has no exceptions. Fiberglass tooling is cheaper to start, so for very short runs, one-off shapes, or a market test where the volumes do not justify steel tooling, it remains a rational choice. The point is to know what you are buying: lower upfront cost, higher per-unit variance, more breakage in transit.
Side by side
| Factor | ABS | Fiberglass |
|---|---|---|
| Impact behaviour | Deforms and recovers | Stiff, then cracks |
| Tooling cost | Higher upfront | Lower upfront |
| Batch consistency | Injection-moulded, repeatable | Depends on lay-up and operator |
| Suitability for volume | Amortises across volume | Suits short runs and one-off shapes |
| Transport damage | Lower | Higher – the common failure we saw |
| Repair | Usually replace the part | Repairable, but repairs are visible and variable |
What we build now
Our hard shells run in two materials, ABS and aluminium, and the choice is made per model rather than as a blanket rule. The aluminium shells are the ones most distributors open with:
- T21A – slanted shell sheds water before the fabric loads, two-layer aluminium floor, 15 cm closed, 52-63 kg depending on shell size.
- T32A – roof racks built into the closed lid, 21 cm closed, 108 cm open, 71-80 kg.
- AT12 – lateral Z-fold opening along the vehicle side, 18.5 cm closed, 72 kg, uncoated poly-cotton fabric at 1,000 mm because the shell sheds the water first.
Custom shell sizes and fabric colours are available on these models – send the closed footprint you need and we will confirm the tooling window.
Questions to ask any supplier
- What is the shell material, and is it moulded or hand-laid?
- What is the damage rate on shipped units, and who carries it?
- Are spare parts numbered and stocked, and do they fit earlier production?
- What is the tooling cost if I need a custom size, and what volume does it assume?
Warranty is 12 months; MOQ depends on model and customisation. Send your requirements through the enquiry form.
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