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Case Study

Commercial Truck
Sleeper Bunk

Commercial Vehicle bunk systems


Commercial Trucking operators are required to take a rest period of 15 minutes for every 3 hours of driving. On long-haul team sleeper cabin configurations, there can be the option to have a two bunk system, lower and upper.


The upper bunk is not a popular item. In many cases it simply become a storage shelf or even removed because of its unnecessary added weigh to the vehicle.  accessory. When it is a desired item whether it's included with the original purchase of the vehicle or bought as an accessory, the overall cost and weight are the determining factors. 


As standard equipment or an accessory, the cost of upper bunk turned off customers.


Goal: My focus is on the customer point of view coupled with market research, employing new manufacturing techniques and evaluating material choices.


After several unique design iterations, I focused on re-purposing existing components used elsewhere on the vehicle in order to reduce extra tooling and additional expense, the door frame was the perfect component for this application.


  • Minimal tooling costs

  • Manufacturing simplified

  • Weight reduction of 5 pounds

  • Cost reduction of 50%

bunk systems-sketches.jpg

Bunk system concept 

Finite Element Analysis (FEA) evaluation of bunk concepts

Common Parts: Door frame used for bunk frame

3D Cad evaluation

Digital mock up

Full scale functional prototype 

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