This graduation project, conducted in collaboration with BMW Motorrad and TU Delft, presents the BMW GS Proterra concept: a repairable and sustainable aluminium luggage storage system (LSS) developed for the BMW R 1300 GS Adventure. The objective is to create a concept that facilitates effortless lifespan extension through circular design strategies, while addressing the diverse needs of GS riders.

Problem
The construction of the existing aluminium GS Adventure LSS presents significant challenges with regard to disassembly, repair practices and reuse. The used connections are non-reusable rivets, making it almost impossible to replace individual components. Unfortunately, this often results in the entire LSS being replaced. This premature disposal is further driven by the desire of GS riders to maintain the ‘as new’ appearance of their motorcycles and LSS.

Research and analysis
Research into the behavior and experiences of BMW GS riders with regard to damage and repair practices revealed that most damage occurs at low speeds. Although 60% of users attempted to repair the damage themselves, barriers such as inaccessible parts and complex assembly processes prevented more widespread repair practices. Assessment methods such as Hotspot Mapping and Disassembly Mapping confirm that priority parts are difficult to access due to high-force, non-reusable connections, and that a large number of dependent actions are necessary before removal. This makes successful roadside repairs and efforts to extend the LSS’s lifespan unlikely.

Design strategy
In response, the concept of a sacrificial design was developed, involving the incorporation of features designed to absorb external impact forces. This reduces the forces that reach the core structure and minimizes its plastic deformation drastically. The sacrificial parts that absorb impact forces are designed to deform and are easily replaceable, thereby making it possible to prolonging the LSS’s lifespan and retaining value for the GS rider. Additionally, this design strategy allows visible wear and tear to be accepted as part of the product’s robust and durable narrative.

Concept
The BMW GS Proterra concept is an all-terrain aluminium LSS that demonstrates how sacrificial design can enhance durability, user engagement, and emotional attachment. The architecture of the system places vulnerable components safely inside, while positioning easily replaceable sacrificial parts externally. GS riders have the option of retaining signs of wear as evidence of their past adventures or restoring the appearance by replacing these parts. The final concept was validated using a high-fidelity aluminium prototype, confirming the ease of part replacement.

Future application
The project offers valuable insights for both BMW Motorrad and TU Delft by demonstrating how repairability and sustainable product design can align with aesthetic and functional objectives. The GS Proterra is a valuable source of inspiration for the implementation of circular design in mobility products and has the potential to influence future product development within BMW Motorrad.