Genesis Products launches EV interior design with ultra-lightweight

 Friday, October 3, 2025

An important turning point in the fusion of advanced interior design with electric vehicle (EV) technology has been reached with the introduction of the all-electric Coachmen RVEX. The car’s remarkable 270-mile electric range is not just the result of battery engineering; it is also a breakthrough in materials science and the production of interior components, led by Genesis Products Inc., a market leader in wood components and laminated panels.

As the interior supplier, Genesis’s role went beyond mere aesthetics. They were tasked with a critical mission: significantly reducing the curb weight of the RVEX to maximize its performance metrics—a challenge that resonates across the entire transportation, residential, and contract furniture sectors as the drive toward sustainability and efficiency accelerates.

The project necessitated a departure from traditional wood-based components, which are too heavy and susceptible to moisture for the demands of an all-electric vehicle operating in diverse environments. Genesis engineered a revolutionary solution by integrating three next-generation, ultra-lightweight materials:

1. G-Lite Plywood: An exclusive, high-performance lightweight plywood designed to offer the structural integrity of conventional panels at a fraction of the weight.
2. G-Strong PET Foam-Core Panels: This recycled material, derived from post-consumer plastic bottles, replaces heavy plywood or Oriented Strand Board (OSB) in the RV’s structural elements. Its closed-cell structure boasts a key advantage: zero moisture absorption, making it impervious to the delamination and rot issues common in traditional RV construction. Crucially, these panels also effectively double the R-value (thermal resistance) of their wood alternatives, significantly boosting the vehicle’s energy efficiency and passenger comfort.
3. Lisocore: A patented, material-efficient construction material with a distinctive three-dimensional, corrugated core structure. Lisocore allows for high load-bearing capacity and stiffness while consuming significantly less raw material (up to two-thirds less than conventional wood panels).

By strategically combining these materials, Genesis’s engineering team, led by Kyle Rasler, achieved astonishing results. The cabinetry alone realized a 45% weight reduction, saving over 290 pounds compared to a conventional build. Furthermore, the floors, ceilings, and walls—constructed with the G-Strong PET foam-core panels—are 50% lighter than their OSB or plywood counterparts.

“Coachmen came to us with the primary goal of reducing weight in the unit. We turned to innovative materials like our exclusive G-Lite plywood and our G-Strong PET foam-core panels to achieve our goals,” said Kyle Rasler, Genesis engineering manager, highlighting the critical nature of material selection in EV design.

The focus on lightweight engineering did not come at the expense of design or luxury. The interior of the RVEX reflects contemporary trends that emphasize:

• Aesthetic Continuity: The use of high-performance luxury vinyl featuring sophisticated stone and woodgrain finishes ensures a high-end, residential feel that is also extremely durable and easy to maintain. This echoes the broader 2026 interior design trend of balancing tactile, organic aesthetics with the practical resilience required for multi-functional, adaptive spaces.
• Intelligent Storage: To maximize space in the compact Class B motorhome format, the interior incorporates innovative storage features, notably two fully integrated pull-out pantries. This focus on “hidden storage solutions” and maximum space utilization is a key demand driver in both compact residential units and recreational vehicles.
• Resilience and Sustainability: The choice of PET foam-core panels, made from recycled plastic, aligns with the industry-wide shift toward sustainable luxury. These materials offer longevity and resistance to humidity—a crucial feature for vehicles used in varied climates—while reducing the environmental footprint through the use of upcycled content and lower-weight shipping.

Zach Eppers, general manager at Coachmen RV, praised the collaboration, stating, “We couldn’t have done this without Genesis. They saw our vision and had not only the design and engineering capabilities, but also the drive to help bring it to fruition.”

The resulting interior is not just lightweight and resilient; it serves as a high-performance benchmark for the entire industry. This successful deployment of advanced, lightweight composite technology firmly establishes a new paradigm: that sustainable material innovation in interior construction is not just an eco-friendly option, but a direct and essential contributor to the functional performance and range of electric vehicles. This partnership proves that the path to a greener future on the road runs directly through the engineering expertise of interior component manufacturers.

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Tags: cabinetry weight reduction, Coachmen RVEX, EV interior components, Lightweight interior design, RV interior trends