Design and Analysis were contracted to perform structural analysis support for the complete redesign for JLG’s telehandler product range. The redesign brought increased commonality between different machine variants. Design and Analysis developed a new approach of compete vehicle modelling within the FEA environment to obtain a complete picture of the effects of each loading scenario, using non-linear analysis to accurately represent contacts. We also introduced advanced non-linear explicit analysis to simulate the ROPS (Roll Over Protection Structure) and FOPS (Falling Object Protection Structure) testing. This allowed the design team to the gain confidence of a successful test prior to regulatory physical testing and manufacture.