OVIK CROSSWAY - World Class Armoured Vehicle Manufacturers

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Building the capability our customers require.

Every CROSSWAY vehicle is individually tailored to meet specific customer requirements. We don't believe in 'off-the-shelf' solutions, because we know that each of our customers has a unique purpose for their vehicle or fleet of vehicles. Whether it's an armoured border patrol vehicle for desert operations, a fire tender for fighting forest fires or an off-road ambulance for arctic conditions, every vehicle solution is subject to intensive assessment, intelligent design and skilled manufacture.

Before we commit to build a new vehicle or range of vehicles we expect to spend time with our customers, understanding their particular needs and designing a CROSSWAY based solution to fulfil their exact requirments.

We call this phase 'ideation'... it's a process of listening, understanding and interpreting customer and end-user requirements. The ideation phase is at the very core of OVIK's approach to vehicle design; ideation informs our decision making processes and helps us create the vehicles our customers need. Ideation also cements the relationship between the OVIK design team and the customer and starts the process of giving the end user a true sense of ownership of the design.

Part of the ideation process involves OVIK designers producing visual concept sketches and detailed design renders - to help the the customer understand how the final product will work and importantly, what it will look like. Of course, it's our job to guide the customer; we know what can and can't be acheived technically and we know that the customer's budgetary constraints are a vital consideration. Some customers get deeply involved in the ideation process whilst others are happy to leave the detail to us; it's the customer's choice.

Once the customer is content with the design concept we can provide project costs in order to allow the customer to make the final purchase decision.

design of the armoured vehicle

The IDEATION Process.

Phase 1 - CONCEPT IDEATION (Understanding the Requirement)

This is an emormously important part of the design process and one which, if not managed correctly, will set the project off on completely the wrong track. It always amazes us how badly this process is handled in so many of the specialist vehicles we see constructed.  

It's vital to understand execatly what the customer wants.  Surprisingly perhaps, many customers are not entirely sure what they actually want or need in a vehicle, they often just know that they can't find what they're looking for in the general marketplace. Helping the customer understand the real requirement is were the OVIK design team adds enormous value. Through a process of open, frank discussions and by posing a number of standard yet detailed questions, we are able to construct a theorectical vehicle 'mission profile' which helps us start to define the vehicle design in its broadest sense.  We ask simple questions such as: 'where will the vehicle be used? 'What type of terrain will it encounter?' and 'what is the primary use of the vehicle'.... 'how much payload or cargo will the vehicle need to carry?'.... 'what are the secondary or alternative roles of the vehicle'.... 'how far must the vehicle travel between fuel stops'... 'what type of fuel is preferred' etc etc.

As we progress through the fundamental requirements we begin to understand more about the type of chassis required, the number of axles, the braking system, the size of fuel tanks required, environmental considerations such as operating in extreme hot and cold climates and all the automotive and engineering implications which must be considered in view of the answers we receive. 

Soon we'll have sketched out two or maybe three alternative chassis systems... perhaps a heavy duty 4x4 or a 6x6 with various engine and transmission options best suited to the vehicle's mission profile.    

Then we move onto the concept vehicle body design.... Again we ask fundamental questions 'how many crew?'.. 'how many passengers?'... 'what types of equipment and cargo are carried?'... 'does the vehicle need to be armoured?'... 'If it needs to be armoured, what are the threats and what level of protection is required?', 'What type of environmental controls are required... Airconditioning perhaps....heating... both?', 'What electrical system is required...12v / 24v...?' 'Will the vehicle need to wade in deep water? If so.. to what depth?' etc ect...

The above questions are purely illustrative and by no means exhaustive; this is a very detailed and important process.

From this Phase 1 process the OVIK design team will be able to formulate initial vehicle design proposals with reasonably accurate costings for manufacture, supply and support. 

By now the customer will have a series of sketches, renders and images of the proposed vehicle along with a broad technical specification, rough order of costs and project lead times.  Armed with that information the customer can make much better informed procurement decisions.

What Does All of this Cost?

This process is generally conducted outside of contract, with no obligation and of course, free of charge.  We hope that Phase 1 ideation leads to further contracted design work and ultimately to sales; however, if after Phase 1, the customer decides not to progress with the order there are no commitments or obligations whatsoever.

public order armoured vehicle

equipment stowage on the armoured vehicle


TOP LEFT IMAGE (Displayed here with kind permission) - In this case we were approached by a very prestigious customer from the MENA region.  Broadly, the customer needed a highly reliable vehicle, able to operate in extreme hot temperatures (up to 50°C), in dusty and sandy conditions, with an 800km range and a crew of four. This image is one of the very early concept sketches - produced during the first days' discussions with the customer.


TOP RIGHT IMAGE - This image was produced by the OVIK design team in response to a request from an existing customer for an armoured vehicle which would be optimied for public order (riot) duties.  Based upon OVIK's unique experience of designing public order armoured vehicles for UK police, we were able rapidly to produce a vehicle concept with a number of specialist features which would optimise the vehicle for public order missions.  


CENTRE LEFT IMAGE - This rendered image is part of a set of images produced for an EU parter company and formed part of a submission for a public tender process. The requirement is for a very lightweight vehicle with high payload to be used by airborne forces. This is an ongoing project and is referred to as the CROSSWAY MULE project.


BOTTOM LEFT IMAGE - Renders of internal layouts - which include consideration for ergonomics, human integration and equipment stowage are useful tools which help customers through the design process.


BOTTOM RIGHT IMAGE - This concept image was produced for a mining company which requires a series of utility vehicles with a 'cherry picker' and mobile workshops capability.


interiror design of the armoured vehicle

concept design of the armoured vehicle

The Ideation Process


Once the customer is content that the solution proposed as a result of the concept ideation phase meets the requirement, ideation phase 2 can commence.  At this stage the OVIK design team commence the process of producing detailed computer aided design (CAD) models and engineering drawings.  All the various technical elements, such as the electronics system, protection systems, lighting, instrumentation, external accessories, special body design etc are brought together into one holistic CAD model package.  This process helps clarify the design whilst also reducing engineering risk and cost. As the CAD model evolves the customer is able to watch the design crystallise. At this stage the project is still a long way from what we term design 'freeze' and both customer and engineers will make coninual design amendments to ensure that everything necessary can be packaged into the vehicle and that every system works in harmony - in the virtual world at least.     


CAD image design of the armoured vehicle

cross section of the armoured vehicle

design stages of the crossway


The OVIK design team are able to make frequent rendered images from CAD which are then transmitted to the customer for assessment and comment. In this instance, images were produced as a tool to aid in discussions with the customer who resides overseas.


This 'sectioned' CAD image was produced as a tool to aid in customer discussions and design 'sign off'; the customer in this instance being in SE Asia and not able to attend regular design meetings.


OVIK uses CATIA and SOLIDWORKS software to ensure efficient design management. All designs are fully supported by imagery that can easily be transmitted to the customer for discussion and comment.


Ultimately, OVIK designers use highly sophisticated modelling and rendering software to produce a near photographic 3D image of the final design solution. This is a CGI image produced in house.

CGI image of the armoured vehicle

The Ideation Process

Phase 3 - PHYSICAL IDEATION (Modelling & Prototyping)

For large or complex contracts a full prototype system will be employed. Rapid prototypes, scale models and of course fully functioning production prototypes are all possible and in some cases, essential.  


fully functioning proto type

scale mock up of the armoured vehicle

fully functioning scale model armoured vehicle


TOP LEFT IMAGE - Creation of a 1:1 scale mock-up space model. Space models, constructed from lightweight and cost-effective materials are of enormous benefit during the concept and prototyping process.  In this instance a space model was created to aid the design of the interior of an armoured vehicle. During ideation the customer's requirements for space, personnel and equipment stowage were articulated and using in-house craftsmen, we were able to create an accurate space model which in turn generated debate in respct of stowage, seating, ergonomics etc. ultimately resulting in a design which suited the intended purpose perfectly.


TOP RIGHT IMAGE - We carry out all styling and body panel creation in-house. Styling starts with 2D drawings and progresses through 3D renders, CAD and then, ultimately a 1:1 scale 3D model is created in either foam, model board or clay - from which we produce tooling to make bespoke body panels.


CENTRE LEFT IMAGE - Full scale, operational prototypes are produced to support complex design programmes.


BOTTOM LEFT & RIGHT IMAGES - Full realisation of customer's requirements is met at every level during the physical ideation or prototyping phase. 


customer requirements of the armoured vehicle

end design stages of the armoured vehicle