Rear rack for police vans

SPE Award 2025 - “Materials & Technologies” category

Fast facts

Vehicle modification: MOSOLF SE & Co. KG
Raw material manufacturer: AKRO-PLASTIC GmbH
Machine manufacturer: Fraunhofer IWU / 1A Technologies
Parts manufacturer: Fraunhofer IWU / 1A Technologies

3D-printed rear rack for battery-powered police vehicles

Electric drives are an essential component for reducing CO₂ emissions in the transportation sector. At the same time, high-voltage batteries add weight, which reduces the permissible payload. The newly developed, 3D-printed rear rack addresses this issue: it significantly reduces the system weight, makes optimal use of the available space in the rear, and maintains full operational capability in everyday police work.

Excellent collaboration and award-winning result

The rear rack was developed in close cooperation between Fraunhofer IWU, 1A Technologies, and MOSOLF Special Vehicles GmbH. The rack was custom-designed for the extra-long version of the Mercedes-Benz Vito Tourer Pro and received the 2025 SPE Automotive Award in the Materials & Technologies category. The jury praised the successful combination of lightweight construction, functional integration, and safety-related usability.

More payload, more organization, more safety

The combination of tailor-made design and AKROLEN® PP ICF 30 AM black (8344) creates a holistically designed product:

• Significantly lighter: A weight reduction of over 25 kg compared to the previous retrofit solution (>50 %) reduces the system weight to 19.5 kg.

• More storage space: Up to 10 % additional storage space; the upper shelf area has been increased by 8 %.

• Easy functionalization: Accessories and functions can be easily integrated.

• Precise fit: The design is automated based on a 3D scan, making the best possible use of the space available in the vehicle.

• As safe as the standard version: The new solution meets the same safety requirements as the previous system.

• Powerful material: The high specific strength and stiffness make the rack resilient while keeping its weight low. The good processability without pre-drying allows for uncomplicated use while achieving a steady part quality.