Sportsmobile at Overland Expo West 2025

In May, the Sportsmobile team hit the road for one of the biggest events in the adventure travel world, Overland Expo West 2025 in Flagstaff, Arizona. With more than 28,000 attendees, this year’s event was the largest to date, bringing together overland enthusiasts, gear heads, vanlifers, and explorers from all 50 states and 20+ countries.

We brought a crew of five and three of our most popular van builds to showcase. Beyond showing off our latest work, we took the opportunity to immerse ourselves in the overland community, talk shop with fellow builders, and learn what’s on the horizon for the adventure travel space.

What We Saw

Overland Expo continues to grow, and this year the energy was undeniable. According to show organizers, 41% of attendees were brand new to Overland Expo, which speaks volumes about the surge in interest in the overland and adventure van lifestyle. Whether it’s weekend warriors or full-time travelers, more people are hitting the road and seeking vehicles that can support both comfort and capability.

We saw a noticeable uptick in interest around vehicle self-sufficiency; water systems, solar solutions, and gear for long-range travel were everywhere. There was also a big focus on modular builds, with flexibility becoming just as important as ruggedness. A trend that stood out to us was the push for lighter, more compact systems that reduce vehicle weight without sacrificing functionality.

Overland Expo West 2025 showcased just how fast the adventure vehicle space is evolving. There were hundreds of innovative rigs on display, and just as many ideas to spark new thinking. Whether you’re building from a bare chassis or retrofitting your third van, the trend is clear — overland travel is becoming more self-sufficient, modular, and refined.

Here are a few standout innovations and trends we noticed:

• Integrated Lithium Power Systems with Smart Distribution

Several builders and component vendors were showcasing 48V lithium power systems, often paired with Victron Energy or Redarc smart control units. These systems are not only more efficient, but they also support higher-amperage appliances like induction cooktops, air conditioning, and high-flow water pumps without draining capacity too fast. We saw more dual-alternator setups and DC-to-DC charging from vehicle alternators that outperform standard shore power setups.

• High-Clearance Suspension Upgrades

There was a huge focus on suspension tuning for full-size vans, especially Transit and Sprinter 4×4 platforms. Van Compass, Agile Offroad, and Owl Vans were front and center, demoing lift kits, custom-tuned Fox shocks, and progressive-rate leaf springs that dramatically improve ride quality over washboard trails and uneven terrain. These aren’t just cosmetic upgrades — they make a real difference in vehicle control and occupant comfort on long backcountry routes.

• Advanced Water Filtration and Heated Plumbing Systems

Cold-weather adventurers got a treat this year with new heated fresh and grey water tanks, as well as inline UV purification systems that let you draw and filter water directly from natural sources. We saw multiple vendors showcasing RecPro and Truma AquaGo systems with automated winterizing capabilities, which are game-changers for year-round travel.

• Solar That Works Smarter, Not Just Bigger

Rather than loading roofs with giant rigid panels, we saw a shift toward flexible solar skins and high-efficiency, low-profile panels from companies like Sunflare and Zamp Solar. These integrate better with roof racks and don’t interfere with pop tops or rooftop gear. Paired with smart MPPT charge controllers, these systems are enabling more reliable off-grid power without sacrificing vehicle design.

• Sustainable Materials and Lightweight Panels

Builders are beginning to embrace eco-friendly composite panels, bamboo cabinetry, and low-VOC adhesives. Not just for environmental reasons, but because they’re lighter, more durable, and reduce interior noise. It was encouraging to see these options alongside traditional builds, particularly for buyers who want a quieter and more thermally efficient van.

• Security and Connectivity Tech

With more people living or working full-time in their vehicles, we also noticed an uptick in smart monitoring systems. GPS trackers with remote disable functions, Starlink-compatible routers, and full-van camera networks were being integrated into more builds. A few vendors were demoing mobile app-controlled climate systems, allowing you to pre-cool or heat the van before returning from a hike or errand.

We brought five members of the Sportsmobile team out to Flagstaff, and each of us came away with something different, from customer conversations to hands-on testing and scouting the latest gear. Here’s a closer look at what stood out to each of us:

Brian – Customer Connections Are Evolving

I spent a lot of time in and around our vans talking with past customers, new van owners, and folks just starting their overlanding journey. They’re looking for vans that double as mobile offices, needing multi-use spaces, quiet zones, and stable onboard connectivity (like Starlink setups with hard-mounted routers). It’s no longer just about weekend escapes, these builds are becoming lifestyle hubs. That shift is driving demand for more integrated power management, dedicated charging ports, and modular seating that can pivot between travel, work, and rest modes.

Paul – Stronger Partnerships, Smarter Integration

For me, this event was about reconnecting with industry partners and building new supplier relationships. One thing that came up a lot was component interoperability. With so many new innovations out there, from smart inverters to remote-controlled HVAC units, integration is key. We’re starting to see systems manufacturers building better APIs and data-sharing capability, which means smarter vans that are easier to monitor and troubleshoot remotely. These deeper tech stacks are creating new opportunities for smarter diagnostics and customer support long after the build is done.

Cody – Gear Innovation Keeps Pushing Limits

As our go-to gear guy, I was all over the show, and there was no shortage of new tools and tech. A few standouts: lightweight recovery boards made from recycled polymer blends, LED area lighting with adjustable color temperature, and low-profile roof racks designed specifically to work around solar, and MaxxAir fans. I also spent time with a company demoing modular fuel and water storage systems that can be mounted both internally and externally,great for customers with different seasonal needs. It’s clear that accessory companies are getting more thoughtful about design integration and space efficiency.

Caleb – The Overland Market Is Maturing Fast

This year’s show really emphasized how broad the overlanding world has become. From Unimogs and EarthRoamers to bare-bones roof top tents, the spectrum is massive, but what’s most interesting is that people are getting more intentional about their setups. Instead of “maxing out every feature,” we’re seeing buyers who want builds tailored to their terrain and travel style. That means simpler plumbing, fixed sleeping areas, and more manual over electric systems for those going truly off-grid. It’s a reminder that there’s no one-size-fits-all solution, and our custom build approach fits perfectly with that mindset.

Diane – Learning Through Shared Experience

I spent a lot of time attending classes and panel sessions, including a standout one with full-time overlanders who shared the raw reality of life on the road. What stuck with me was the importance of redundancy and real-world maintenance planning. One panelist talked about carrying a full spare water pump and how a $90 part saved their Baja trip. That kind of insight reinforces how valuable smart component selection and layout accessibility is in our designs. Another takeaway: community matters. People are hungry for education, connection, and brands that support them not just with products, but with real expertise and empathy.

Field Testing in the Wild

We took our vans off-grid in Northern Arizona to put them through their paces. Every trip like this gives us a chance to see how our builds perform in real-world conditions and how we can continue to refine our craftsmanship. When you’re miles from the nearest pavement, every cabinet latch, water tank, and sleeping setup gets put to the test.

Vans We Showcased

For those who couldn’t make it to the show, here’s a look at the three builds we brought: