Clemson University has unveiled Deep Orange 16, a next-generation, semi-autonomous vehicle designed to transform emergency response in extreme conditions. Developed by graduate automotive engineering students in the university’s acclaimed Deep Orange program, the vehicle merges advanced technology with mission-critical functionality to enhance the speed, safety, and efficiency of rescue operations.

Sponsored by the Virtual Prototyping of Autonomy-Enabled Ground Systems (VIPR-GS) Research Center and developed in collaboration with the U.S. Army and other strategic partners, Deep Orange 16 is engineered to tackle some of the toughest challenges in high-risk rescue scenarios—reducing response time while limiting the number of personnel needed in the field.

Inspired by the real-world challenges faced during Hurricane Helene, the Deep Orange 16 team engineered the vehicle to support critical disaster response efforts. On its outbound journey, the vehicle can deliver a full pallet of emergency supplies to affected areas. For the return trip, the vehicle operates autonomously—transporting up to six individuals, including injured passengers, to safety. Capable of reaching the scene within the “golden hour,” the vehicle also generates a high-resolution digital terrain map for the autonomous return, allowing the original driver to remain on-site and assist ongoing rescue efforts.

Engineered for the Elements

• High-speed, semi-autonomous vehicle with a 350-kilometer range and off-road capabilities built for unpredictable terrain.
• Series hybrid powertrain enables continuous battery charging to extend range and supports near-silent operation for special mission scenarios.
• Designed for real-time deployment, Deep Orange 16 features a lightweight, weatherproof exterior engineered for reliable operation in a variety of environmental conditions.

Innovative Monitoring

• A 360-degree camera system provides full situational awareness, including tire-level views for obstacle detection.
• An AI-powered heads-up display alerts drivers to hazards up to 100 feet away, enhancing navigation and safety.
• Onboard medical monitoring tracks patient vitals in real time, including temperature, heart rate, and perspiration during transport.

Rescue-Ready Interior

• Interior accommodates the transport of six people, including a rotating passenger seat to support multiple operational roles.
• Ergonomic litter loader streamlines patient or supply loading.
• MOLLE storage system offers secure, modular organization of rescue and medical gear.
• Rear hatch fits a standard pallet of supplies, while the clam-shell design enables flexible loading of oversized cargo.
• Integrated exterior compartments securely transport fire rescue equipment.

Deep Orange 16 students and staff with their prototype vehicle on the CU-ICAR campus.

Deep Orange 16 showcases the innovation, technical expertise, and dedication of the 17-member team of graduate students from Clemson’s automotive engineering program. “Deep Orange pushes us to think like real-world engineers,” said team lead Rohit Godse. “We are not just learning theory, but solving complex, high-stakes problems that prepare us to lead in the industry from day one.”

From initial concept to fully functional prototype, the team collaborated with the VIPR-GS Research Center, government agencies, and industry partners to solve practical challenges—gaining hands-on experience that prepares them to enter the workforce as industry-ready engineers. “The Deep Orange program demonstrates what’s possible when academia, government, and industry come together to solve real-world problems,” said Dr. Robert Prucka, Kulwicki Endowed Professor and Chair of the Department of Automotive Engineering. “Our students are not only driving innovation—they’re helping to save lives by improving how we respond to emergencies in the most challenging environments.”

Deep Orange 16 was officially unveiled at the Ground Vehicle Systems Engineering & Technology Symposium (GVSETS) in Novi, Michigan. It will now serve as a test and validation platform for ongoing research by the VIPR-GS Research Center, located at the Clemson University International Center for Automotive Research (CU-ICAR) in Greenville, South Carolina.

Acknowledgment: This work was supported by Clemson University’s Virtual Prototyping of Autonomy Enabled Ground Systems (VIPR-GS), under Cooperative Agreement W56HZV-21-2-0001 with the US Army DEVCOM Ground Vehicle Systems Center (GVSC).

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In March of 1990, Ford Motor Company unveiled a new model SUV, the Ford Explorer. That same year the company had a second, perhaps lesser-known launch, the career of a budding engineer named Jamie Forbes. Now, after 32 years with the industry icon, Jamie conveys a wealth of knowledge and insights to Clemson University automotive engineering students. Among the many lessons he imparts, perhaps the most important is the value of perspective.

After completing his education, Jamie established both his family and career in Farmington Hills, Michigan. Over the next three decades he and his wife, Irene, raised their three daughters, all while Jamie’s career continued to evolve at Ford. Throughout his tenure, he was entrusted with several key roles and helped build departments in optical metrology, mechanical packaging, vehicle engineering, and ergonomics.

In 2011, Jamie hired a young Clemson graduate who had just completed a program called Deep Orange. “He was amazing,” Jamie recalled. “And what I’ve found is that when you have a great engineer and you need more, you ask if they any friends because smart people tend to hang out together.” In the years that followed, Jamie recruited more than 50 Clemson engineering graduates to Ford, creating a valuable pipeline of talent. “It got to the point where I knew if you had worked on Deep Orange, I was going to hire you.”  This growing connection led to personal relationships with professors and eventually, Ford’s sponsorship of Deep Orange 10, a self-driving passenger vehicle prototype aimed at reclaiming drivetime for families, students, and business professionals.

As Jamie’s industry career was nearing its end, he was approached about one final role — an opportunity that would allow him to pour into the very program and students he’d come to admire during his time at Ford.

Forbes in 2021 as a representative of Ford Motor Company consulting with Clemson University students working on Deep Orange 10.

In 2023, after retiring from Ford, Jamie became a professor of practice within the Clemson University Department of Automotive Engineering. With decades of industry experience, Jamie relishes the opportunity to teach, advise for Deep Orange and mentor the next phase of the engineering workforce. “I came here and got to somewhat reinvent myself,” Jamie shared. “Engineering has given me everything, and I feel a responsibility to give back by teaching the next generation”

A major draw to this new role was the Clemson University International Center for Automotive Research (CU-ICAR) in Greenville, SC, home to the Department of Automotive Engineering and more than 20 industry partners. “It was a very comfortable transition for someone with my background because it feels somewhat like an industry setting. It’s a perfect blend between academia and industry,” he recalled. Jamie also emphasized the uniqueness of the automotive engineering program, noting “Typically, these classes are part of mechanical engineering departments that have been in the same building since the 1920s. That’s not the case here. This is a custom-built organization with facilities that directly mimic the industry.”

As a relatively new resident of Greenville, Jamie and Irene enjoy exploring all the Upstate has to offer, especially outdoor activities. They’ve already hiked popular local trails like Paris Mountain and Table Rock, but their favorite trek is the monthly trip to Maine to visit their grandchildren. With two grandkids, ages 3 and 1, Jamie — also known as ”Papa” — cherishes watching them grow and observing the interactions between his wife, their daughter, and the next generation. It’s that same sense of perspective that makes Jamie such a valuable mentor to his automotive engineering students.

After three decades in the mobility industry, Jamie understands his students will need more than just the technical skills of engineering. From advice on entering the workforce to mastering communication and understanding global policy, Jamie aims to fully prepare his students for their future careers. “The rigors of graduate education can make it difficult to see what’s ahead,” he said, “but I hope to offer my students the perspective and encouragement they need to push the industry forward. I’ve had my career, and now I get the privilege of helping these motivated young engineers along their journey. I remember being in their shoes, and I know the incredible, rewarding future that lies ahead for them.”

Forbes, now in his role with the Department of Automotive Engineering, provoking thoughtful conversations with the cohort of students developing Deep Orange 17.

When he first visited the Clemson University International Center for Automotive Research (CU-ICAR) during a high school summer program, he never imagined a career at a defense company just down the road, but a decade later that’s exactly where we find Drew Girshovich.

The Rock Hill, SC native grew up with little awareness of Clemson University, much less CU-ICAR, yet it’s a place that would come to play a key role in his educational experience and launch his career. The summer before his sophomore year in high school Drew participated in a program that allowed him to tour the CU-ICAR campus, meet faculty and participate in hands on demonstrations. That visit left an indelible mark on him, sparking a dream that would shape his educational and professional future. “As a 15-year-old car enthusiast, it just blew my mind,” recalled Girshovich. “I told myself, ‘This is where I’m going to end up and I’m going to do everything I can to get to this place.’” And that’s exactly what happened. Drew graduated from Clemson University with a mechanical engineering degree and enrolled in the automotive engineering graduate program. He soon found himself on the CU-ICAR campus fulfilling the goal he’d set just years earlier, but it wasn’t quite what he was expecting.

“Clemson’s undergraduate engineering program was tough, so I expected the graduate work was going to be a huge challenge, and it was, but in an exciting and engaging way,” Drew explained. “It was less of a list of specific things you have to learn and more like ‘What are you passionate about?’ and then ‘Well let’s go learn and research how to do it.’” For Drew the answer to that question was design engineering. “To be able to design and create something that you can hold, and then give it to someone and say ‘I made this for you to make your life better’ is something I’ve always been passionate about.” Little did he know that his passion for design engineering and cars would lead him on a two-year journey that he would call one of the best experiences of his life.

During his time on the CU-ICAR campus, Drew participated in Deep Orange, an immersive 24-month concept development program that produces a prototype vehicle addressing real-world mobility challenges. “I learned so much from Deep Orange that you just can’t learn in a classroom,” said Drew. “It’s one thing to design something, but the process of actually making it for a customer is very different.” The experience not only shaped his technical expertise, but also his approach to collaborative work. “Deep Orange was crazy and hectic, but in such a good way. It taught me about not just being an engineer, but also being a team player, leadership, and how to interact with the customers and industry partners.” His time in the program and exposure with CU-ICAR partners would ultimate help Drew achieve his next goal, a design engineering role in the city he had come to love.

With graduation in sight, Drew and his wife, Olivia, began to evaluate the next phase of their lives. For the couple that loved spending time on Lake Hartwell, attending Clemson Football games, and exploring the Upstate of South Carolina, the idea of moving north for a design engineering job seemed less than ideal. “I had been told by professors, and I experienced it firsthand through Deep Orange—there’s just a different energy here than in the cities where many of the design engineering jobs are located,” Drew explained. “Being on the CU-ICAR campus in Greenville allowed us to fully experience the city. There’s always something going on with outdoor experiences, festivals and unique places to eat. It’s a place we fell in love with and didn’t want to leave.”

With an affinity for Greenville in mind, Drew was guided by Deep Orange faculty to explore Applied Research Associates, Inc. (ARA), a multi-national company delivering research, leading-edge products, and innovative solutions that address problems of national importance. Better yet, ARA was already an established partner of CU-ICAR and had an office just minutes from campus. “I never would have guessed I’d end up in the defense industry,” Drew admitted. “But my time at CU-ICAR opened my eyes to all the avenues I could go with my automotive engineering degree. The program provides such a broad skill set that is valuable in any workplace, and it enabled me to stay in Greenville —something that was important to me.”

Now an established design engineer with ARA, Drew is excited to once again develop new goals and ideas on the CU-ICAR campus as the two organizations continue to partner on research initiatives. “When I joined ARA, I was thrilled to learn about the existing collaboration with Clemson University. With all the resources and expertise at CU-ICAR and ARA, I know the partnership is going to be incredibly productive,” Drew said. “I can’t wait to see what we can accomplish together in the future.”

As Clemson University and ARA continue their partnership, there’s no doubt that Drew’s story is just getting started—and the future holds even more exciting possibilities for this talented engineer and innovator.

Each year, natural disasters cause significant damage and disruption to the nation’s transportation infrastructure, destroying delivery routes to affected populations and complicating efforts to assess the situation.

In 2022 alone, natural disasters caused an estimated $165.1 billion in damages in the United States, according to the U.S. National Oceanic and Atmospheric Administration (NOAA).

To expedite the delivery of supplies and to gather real-time data for emergency responders, Clemson University students at the International Center for Automotive Research (CU-ICAR) in Greenville, S.C. developed an off-road reconnaissance and relief vehicle that can navigate all on its own.

Equipped with lidars, cameras and high-accuracy GPS (GNSS), the autonomous vehicle can sense and navigate on unknown terrain. The vehicle can reach 45 mph, scale 18-inch high obstacles, maneuver 60% grade surfaces and pivot 360 degrees in place in two seconds.

Its adaptable series-hybrid powertrain allows for powerful maneuverability and improved fuel economy as well as silent travel in electric-only mode. When the vehicle arrives at its destination, it can deliver emergency supplies and act as a mobile generator in case of electricity disruptions without putting humans in harm’s way.

The vehicle is a result of Clemson’s flagship rapid vehicle prototype program, Deep Orange, housed within the University’s two-year master’s degree focused on systems integration in automotive engineering. To make such an ambitious project possible, two cohorts of Deep Orange students collaborated across three years to develop this autonomous, high-speed, off-road relief vehicle from the ground up.

Students worked with faculty and staff at Clemson’s International Center for Automotive Research (CU-ICAR), along with the project’s primary sponsor U.S. Army DEVCOM Ground Vehicle Systems Center (GVSC).

Clemson announced its strategic partnership with GVSC in 2020 when the University founded its Virtual Prototyping of autonomy-enabled Ground Systems (VIPR-GS) center, backed by the U.S. Department of Defense. The partnership was designed to propel research breakthroughs in off-road vehicle autonomy, powertrain electrification, and digital engineering tools to more effectively support the mission of GVSC.

“Reliable and robust off-road driverless technology is critical to developing the next generation of military mobility vehicles. Even more critical is developing skilled and experienced engineers who can continue to drive innovation in our sector in the future. This project addresses powertrain electrification and digital engineering processes, which are key development areas for GVSC. Along with autonomy, these development areas are the driving forces behind GVSC’s research partnership with Clemson.”
– David Gorsich, U.S. Army Chief Scientist at GVSC

After the student team graduates, the Deep Orange 14 vehicle represents a unique and complex state-of-the-art research asset for Clemson, catapulting the University to the forefront of autonomous high-speed off-road research.

“The Deep Orange 14 vehicle provides not only a validation and verification tool for the intricate dynamic modeling of tracked skid steer vehicles in challenging topographies, but also a sophisticated deployment platform for cutting-edge control algorithms and energy management strategies for series hybrid vehicles,” said Assistant Professor Dr. Matthias Schmid, a faculty co-lead for Deep Orange 13/14 and VIPR-GS researcher. “As an advanced sensor platform, it will help us shape the next generation of situational awareness through sensor and data fusion at high speeds in an unprecedented setting.”

Access to such a highly developed research tool with its multilayered system integration is a rare opportunity in academia and distinct research advantage for Clemson, according to Schmid.

“Witnessing the development of a vehicle from the ground up and observing its successful performance while meeting all specifications is incredibly rewarding,” said Kaivalya Khorgade, who served as Deep Orange 14’s chief vehicle engineer. “With its tracked design and advanced series-hybrid powertrain, the vehicle can conquer various obstacles, while its autonomous features, including an array of camera and lidar sensors, offer invaluable data collection and urban reconnaissance capabilities.”

“Being challenged as a student to develop something of this complexity, something at the edge of technology, is an incredible learning experience – Let alone seeing their work live on through the discoveries of our researchers,” said BWM Chair in Systems Integration at Clemson Chris Paredis, who oversaw the Deep Orange program during both cohorts.

“It’s not just making everything work, it’s creating data logging and input capabilities to inform research across autonomy, vehicle dynamics, powertrain performance, thermal management, and more.”
– Chris Paredis, BMW Chair in Systems Integration at Clemson

The Clemson team debuted their design in Novi, Michigan at the 15th Annual Ground Vehicle Systems Engineering and Technology Symposium (GVSETS).

MISSION SCENARIOS

The vehicle addresses two mission scenarios, which students used to determine the vehicle’s technical specifications and critical functions.

1. Cold Weather Disaster Relief Mission

An unexpected snowstorm blocks highways and leaves civilians in need of food, water, and power for electricity. The autonomous vehicle must provide much-needed resources until workers can repair the local infrastructure, traversing unknown off-road terrain to get to the town in time.

2. Urban Reconnaissance Mission

A natural disaster such as a hurricane or flood changes the topography so dramatically that even aerial cameras are not able to discern if the area is traversable. The autonomous vehicle must drive through the area to assess damage, create a digital map and determine whether ground vehicles behind it would be able to pass or get stuck.

CRITICAL VEHICLE FUNCTIONS

Autonomous Off-Road Path Planning

Using LiDARs, cameras, and GPS, the Deep Orange vehicle navigates autonomously through unstructured, dynamically-changing environments. The autonomy algorithms can plan missions through unknown terrain, gathering information and updating maps based on the on-board sensors.

Off-Road Maneuverability

With its 24-inch-wide tracks, the Deep Orange vehicle can traverse almost any terrain. It can travel at speeds up to 45 mph, scale 18-inch-high obstacles and perform a full 360-degree pivot-in-place in less than two seconds.

Landscape Reconnaissance

After a natural disaster such as a hurricane or earthquake, the Deep Orange vehicle can venture out to gather information about the changed landscape and determine the traversability of the terrain to aid subsequent logistical support. Exterior pan-tilt-zoom cameras can be manipulated and viewed remotely while the vehicle moves autonomously. Collected data is compiled into a map to be wirelessly sent via 5G network for analysis.

Series Hybrid Propulsion

The vehicle’s tracks are powered by permanent magnet synchronous motors that can produce 340 kW (456 HP) of peak power per track.  A 53kWh battery allows for eight hours of low-speed silent watch capability.  In addition, a 3.0L V6 onboard diesel generator can fully replenish the battery in 30 minutes, provide additional power for the traction system during high power-demand maneuvers or act as a mobile generator for survivors when it reaches its destination.

Dynamic Research Platform

With an intuitive user interface for remote control and autonomy, the Deep Orange vehicle is ready to be used by researchers working on advanced autonomy, energy management, vehicle dynamics and digital twins. It includes extensive sensor suites for vehicle dynamics, powertrain and energy management, and thermal management. The data for all these sensors are accurately time-stamped and curated to make it available for further analysis by researchers.