Have You Faced These Challenges?
- Your caravan too heavy? Are you losing valuable payload capacity due to heavy MDF furniture?
- Manual post-processing costing you too much time and money?
- Are your customers suffering from moisture-related damage like rotting wooden frames?
Pick a challenge that’s troubling you, and see how we solve it.
| You're Experiencing | Our Solutions |
|---|---|
| Heavy panels eating into your payload? Customers constantly asking for more storage space? | Lightweight structural composite panel: Density as low as 320kg/m³, 40% weight reduction at equal strength. That frees up enough payload to add an entire water tank. |
| On-site edge banding consumes too much time, with workers constantly patching and reworking. | Pre‑bonded edge‑sealed panels: factory‑finished edge banding, 30% faster installation, and furniture‑grade surface aesthetics. |
| Humid environments causing panel swelling and reduced screw‑holding strength? | Moisture‑resistant lightweight plywood: special bonding process delivers enhanced moisture protection and consistent screw‑holding strength. |
| Wooden frames rot, making it impossible to guarantee durability in old RV renovations. | Aluminum‑faced composite panel: zero risk of rot, high structural strength, ideal for load‑bearing areas such as roofs and floors. |
Features and Benefits
- Free from eight major hazardous metals
- Visually and tactilely similar to natural wood, with realistic grain patterns
- Scratch and scuff resistant; color remains stable without peeling
- Moisture resistant with excellent weatherability
- Static-free; outstanding water resistance
- High screw-holding strength and dimensional stability
- Superior surface flatness
Lightweight Plywood
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Specification
Poplar Hybrid Lightweight Plywood ( Raw Panel ) – Core Parameters.
| Core Material | Poplar Hybrid |
| Standard Size | 2440 × 1220 mm / 2500 × 1220 mm |
| Thickness Options | 2.7, 3, 5, 6, 9, 12, 15, 18, 25, 30 mm |
| Tolerances | Length&Width: +/-1.5mm, Thickness: +/- 0.3mm |
| Density | 400-430 kg/m3 |
| Weight per Sheet (1220 × 2440 mm) | 9 mm: 11 ± 1 kg; 12 mm: 14 ± 1 kg; 15 mm: 17 ± 1 kg; 18 mm: 20 ± 1 kg; 25 mm: 25 ± 1 kg; |
| Moisture Content | 6-14% |
| Screw Strength | 12 mm thickness: approx. 710 N; 15 mm thickness: approx. 740 N; |
| Bending Strength | 12 mm: 26.52 MPa; 15 mm: 54.6 MPa; |
| Modulus of Elasticity | 5,100 MPa (12 mm) to 6,560 MPa (15 mm) |
| Formaldehyde Grade | ENF & E0 |
| Certifications | DIN 5510-2 S4; FSC; JAS F☆☆☆☆ (Formaldehyde emission ≤ 0.3 mg/L); |
| Fire Behavior | B2 |
| Surface Quality | Class 1 |
| Decorative Films | PP, PET, PVC, HPL |
BIGBAHN Lightweight Panels Engineered for Modern RVs
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Eco‑friendly Ecological Panel
We have a wide range of applications in RVs and are extensively used in the manufacturing of countertops, bathrooms, wardrobes, cabinets, wooden doors, beds, and more.
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PET Foam Board
We outperforms PVC foam board in both density and weight, and is available in thicknesses ranging from 9mm to 25mm. It serves as a premium alternative to traditional wood boards for RV body structures and furniture manufacturing.
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Grille Panel
Our features a PET foam board surface with a GMT backing sheet, available in 2440mm × 600mm with customizable grille widths and finishes. It provides sound absorption, fire resistance, waterproofing, and structural stability—making an aesthetic, high-performance solution for RV interiors.
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GMT Panel
The first layer of the GMT board is a decorative surface material, allowing customization of color, style, and pattern according to preference. A wide range of facing options is available, including wall fabric, PVC, PP, PET, and more.
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Polyester Fiber Panel
Our acoustic panel delivers a noise reduction coefficient of approximately 0.8–1.10, offering sound absorption, thermal insulation, and heat retention. The panel features a uniform, solid, elastic, and tough structure. Formaldehyde emission meets the ≤1.5 mg/L standard, with a test result of 0.05 mg/L.
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Curved Door Panel
Our contoured door panels are premium furniture components engineered specifically for RV, yacht, and aviation interiors. BIGBAHN offers over 20 popular curved and custom‑shaped panel designs, including dedicated L‑shaped panels for RV dinette seating. Surfaces can be laminated with a wide range of decorative finishes such as PP, PET, PVC, HPL, or wood grain paper.
Exploring a Partnership with BIGBAHN
See the latest interiors we’re proud to lead from design to construction.
Why Choose BIGBAHN
We keep your production on track.
Choosing BIGBAHN means building greater confidence and stability into your supply chain.
With a reliable network across Europe and Asia, we fill gaps other suppliers cannot delivering quality panels on time, every time.
Your premier provider for RV interiors
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Extreme Lightweight & ENF-Grade Eco Full-Solution Advantages
As a globally leading service provider of lightweight interior solutions for the RV industry, we have built the following four cutting-edge competitive advantages through deep R&D capabilities and a dual-location footprint in China and Germany.
BIGBAHN is continuously driving the global RV interior sector into a new era — lighter, safer, and greener.
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Cross-Dimensional Material Innovation in RV Panels
The RV industry from traditional wood to high-performance composites, BIGBAHN is helping manufacturers worldwide build lighter, safer, and greener future mobile living spaces.We achieve this by seamlessly integrating aerospace-grade composite materials, such as GMT and PET, our high-performance lightweight plywood.
Frequently Asked Questions
What type of RV interior design do you specialize in?
What type of RV interior design do you specialize in?
We specialize in creating high-quality, custom interiors for recreational vehicles usingadvanced laminates,lightweight materials, and a full range ofprecision components.
From contemporary to traditional styling — we deliver the flexibility to meet your specific needs and help bring your vision to life.
Do you provide support for both design and manufacturing?
Do you provide support for both design and manufacturing?
Yes, we offer end-to-end solutions — from design consultation to full-scale production.
We leverage best-in-class technology and advanced manufacturing capabilities to deliver your custom interior components with precision, efficiency, and consistency. Our integrated approach ensures seamless collaboration from concept to completion, helping you reduce lead times and accelerate time-to-market.
Our services include:
- Design consultation – Tailored to your brand DNA and performance specs
- Engineering support – Optimized for lightweighting and structural integrity
- Material selection – ENF-grade eco-friendly laminates, lightweight plywood, GMT/PET composites, and more
- Prototyping & tooling – Rapid iteration with production-ready processes
- Full-scale manufacturing – Scalable, quality-controlled production with global delivery capabilities
Whether you need a single component or a complete interior system — we are your design-to-delivery partner for lighter, safer, greener mobile living spaces.
What is the typical lead time from project start to finish?
What is the typical lead time from project start to finish?
We deliver custom interior solutions within standard lead times of 4–8 weeks for most projects.
Complex or large-volume orders may extend to 10–12 weeks. A firm timeline is scoped during your design consultation and confirmed before production begins.
Do you offer sustainable or eco-friendly options?
Do you offer sustainable or eco-friendly options?
Yes. We provide multiple certified green solutions:
- Our composite wood panels are recyclable and carbon-negative — storing more carbon than is emitted during production and use.
- Our PET products are made from 50% recycled water bottles and are 100% recyclable, supporting a circular economy.
Consult our design team to match your sustainability goals with the right material solution.
How do you ensure reliable bonding between the XPS core and the skin layers?
How do you ensure reliable bonding between the XPS core and the skin layers?
At BIGBAHN, we eliminate delamination risks through industrial-grade manufacturing processes.
Our panels are produced using high-pressure lamination with PUR hot-melt adhesives specifically formulated for XPS. Unlike DIY methods that require sanding and perforation, our factory-controlled process ensures consistent adhesion strength. For applications requiring extreme durability, we offer fiberglass-reinforced skins with enhanced chemical bonding — no risk of skin peeling over time.
BIGBAHN Advantage: 100% factory-bonded with rigorous peel strength testing before shipment.
I've heard that XPS against metal or wood can cause squeaking. How does BIGBAHN address this?
I've heard that XPS against metal or wood can cause squeaking. How does BIGBAHN address this?
Squeaking occurs when two rigid surfaces rub against each other under movement or vibration.
Our pre-laminated sandwich panels eliminate this issue entirely — the XPS core is permanently bonded to both skins, creating a single monolithic panel with no independent moving layers.
For installation, we recommend using our factory-finished panels with integrated anti-friction backing, or following our simple installation guidelines that include a polyethylene slip sheet between the panel and subfloor when required.
BIGBAHN Advantage: No field assembly of layers means no squeaking — period.
