THE JOURNEY BEFORE THE HIGHWAY

May 18, 2025

When it comes to Thule racks, there is a long and often unseen journey long before the rack ever makes its way onto the back of a vehicle. They are subjected to crash tests in Thule’s impact lab, spend time at sub-zero temperatures in a freezer and then live under ultraviolet light exposure to expedite wear and tear. Thule racks have a long and rigorous trip long before they ever see any highway miles. In this installment of our Behind the Brands series, we travel to Thule’s HQ in Hillerstorp, Sweden to learn about the creation, design and testing of Thule’s rack line before heading to Seymour, Connecticut. Thule’s North American HQ is filled with welders, machines and a group of employees who are focused on manufacturing the finest quality racks that are sure to hold up to the rigors we subject them to. Get out your passports (make sure they’re up to date) and let’s visit two impressive facilities focused on transporting our favorite gear and equipment.

BRAND HISTORY

Thule was founded in 1942 by Erik Thulin, a Swedish outdoorsman and entrepreneur who started the company by making fishing gear for fellow nature lovers. His passion for the outdoors and clever approach to solving real world transport problems laid the groundwork for what would become a global brand. What began as a small family business in Sweden has since grown into one of the most trusted names in outdoor gear, known worldwide for helping people bring their passions along for the ride. Three decades later, responding to the boom in recreational cycling, Thule introduced its very first bike rack, a tow-bar-mounted carrier released in 1992, establishing the category that still defines much of the brand today. Since then, Thule’s offerings have expanded greatly, and they offer everything from class-leading bikes racks to luggage and gear bags.

After developing a strong name in bike and ski-transportation, Thule set a new standard for roof-loaded storage. In 2009, they launched the Thule Atlantis cargo box, which boasted impressive aerodynamic design and a large capacity. The Thule T2, a rack that we’ve tested and used since the early 2000’s, saw a major update when the T2 Pro XTR was introduced in 2021. It quickly became a benchmark for premium hitch-mounted bike racks thanks to its tool-free installation and integrated wheels for easy transport. Most recently, the Thule Verse is leading the charge for Thule’s bike transportation in North America, they checked all the boxes and redesigned this rack from the ground up.

Each product reflects Thule’s commitment to quality, user-focused design, and adapting to the evolving needs of outdoor enthusiasts and it was awesome to see the sparks fly in the Connecticut manufacturing facility. One of you out there may even get a rack I helped package and push onto a shipping truck.

HILLERSTORP

Hillerstorp, Sweden, the birthplace of Thule and the heart of its design and testing operations. Walking through the facilities, it’s clear that innovation is woven into the culture here. Designers and engineers work hand in hand, balancing functionality with form, and always with the end-user in mind. One fascinating aspect is how global input is integrated U.S. consumer preferences, for example, often differ from European ones, and Thule designs reflect those nuances. The process is rigorous, prototypes undergo crash simulations, extreme temperature testing, corrosion resistance tests, and more. Every rack, box, lock and carrier must not only perform but survive the harshest conditions imaginable.

SEYMOUR

Seymour, Connecticut, home of Thule’s North American headquarters and manufacturing plant. This is where steel turns into structure and components become complete racks. The production line buzzes with energy, precision, and a deep sense of pride. Every step, from welding to final assembly, and quality assurance is handled by a team that genuinely cares about what they’re building. The culture here is strong, with personality and camaraderie shining through even in the most technical moments. Watching these products come together piece by piece highlights the craftsmanship and local investment that go into serving the North American market.

THULE VERSE

When it comes to hitch mount bike racks, the newly updated Thule Verse checks all the boxes for long road trips or daily commutes to the trailhead.

First off, loading your bikes is super easy thanks to a slick single-hook attachment arm that quickly locks down with minimal user input needed to secure the bike in place. Got gear in the trunk? No problem, the patented outboard release handle lets you tilt the whole rack (even when it’s loaded), so you can grab snacks or helmets without playing bike human Tetris. When it’s time to drive without a bike, the rack folds vertically to keep things tidy. And don’t worry about big bikes—the Thule Verse can handle up to 60lbs per tray, 5” fat tires, and 53” wheelbases.

The details are dialed, a rubber-coated ratcheting arm protects your fork, side-to-side adjustable trays accommodate different bike lengths, and the AutoAttach system means no tools, no sweat. There are even integrated locks and clever strap clips to keep everything secure and out of the way. My favorite accessory is the integrated work stand that attaches to the outboard arm of the rack allowing you to do maintenance trailside without being hunched over on the ground. Additionally, you can purchase wheels if you find yourself constantly removing the rack from your vehicle, this makes for easy transportation to and from your storage location.

In short, the Thule Verse isn’t just a rack, it’s your bike’s new best friend and the MVP of your next road trip.

WHAT IT’S LIKE WORKING AT THULE

As the journey winds down, one thing is clear: Thule is more than a brand. It is a global team of makers, thinkers, and doers who care deeply about getting things right. From sleek design studios in Sweden to hands-on production in Connecticut, every part of the process reflects a shared commitment to quality and adventure. This isn’t just about gear, it’s about the people and passion behind it. Whether you’re hauling bikes to the trailhead or loading up for a road trip, you’re carrying a piece of the Thule story with you. Everyone we talked to was happy, proud even that they are involved in helping people move around the world while safely transporting their favorite items with them.

For more information on Thule’s extensive offering, head to Thule.com.