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From Concept to Combat: The Polaris DAGOR

Polaris is a recognized leader in the ATV market and has been very successful with military offerings in the ATV and LT-ATV vehicle classes. Polaris Defense approached Roush to partner on a larger military off-road vehicle called the DAGOR (Deployable Advanced Ground Off-Road). Roush offered its engineering experience and contract manufacturing capabilities to commercialize the program.

What was the challenge?

Polaris aspired to elevate their defense vehicle lineup with the DAGOR – and they delivered. The DAGOR is much larger than traditional Polaris vehicles, featuring a lightweight, off-road chassis capable of carrying up to 9 soldiers. Equipped with a powerful diesel engine, it can be rapidly deployed via air, land, or sea.

The DAGOR plays a vital role in special operations and rapid-response missions, especially on challenging terrain. With so many factors at play, Polaris sought a partner that could prototype, engineer, and manufacture the vehicle to precise weight, modularity, and durability specifications. Roush took on the challenge.

What did we accomplish?

How did we manufacture the vehicle?

Prototype Development

The prototyping phase was critical to ensuring the DAGOR could meet performance requirements for military operations. The vehicle needed to be lightweight yet capable of carrying a full payload — all while maintaining excellent off-road mobility.

Roush teams refined multiple prototypes by testing the vehicles under real-world and simulated conditions. To guarantee optimal performance, feedback from defense experts and Polaris team members helped improve the vehicle’s design to ensure it met the uncompromising standard for military applications.

Engineering

The DAGOR had to be engineered for rapid deployment and versatility. The Roush engineering team used advanced materials to keep the vehicle light and durable. To account for the variation in combat zones around the globe, the DAGOR’s modular design was specifically engineered for easy customization.

In addition to mobility, the vehicle’s design prioritized simple maintenance and user-friendly driving mechanics. Roush engineers focused on creating a rugged, reliable vehicle with systems that could be quickly serviced in the field during military operations.

Contract Manufacturing

Roush exists to commercialize products for global markets — and our work on the DAGOR was no different. The contract manufacturing team worked to scale the production without compromising on quality. Manufacturing and assembling a functional vehicle required exact specifications, a material sourcing strategy, and strict quality control at every stage.

Throughout the production process, the engineering and manufacturing teams collaborated closely to confirm that every DAGOR vehicle maintained the same high level of performance and reliability. This integrated approach helped Polaris ensure the vehicles could be rapidly deployed for operational use.

9
person capacity
4000 lb
payload capacity

What services were provided?

Multiple teams at Roush came together to deliver the DAGOR. Teams included:
Prototype Development
Metal Fabrication
Powertrain Engineering
Electrical Engineering
Contract Manufacturing

What is the impact?

The DAGOR proves that advancements in defense vehicle size and modularity can be achieved while meeting the essential requirements for off-road mobility, payload capacity, and quick deployment. Whether navigating difficult terrain or being airlifted into the field, the DAGOR is a game-changing tactical vehicle and a testament to the power of precise innovation.

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