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Thomas Built Buses
Thomas Built Buses
from Wikipedia

Thomas Built Buses, Inc. (commonly shortened to Thomas) is an American bus manufacturer. Headquartered in High Point, North Carolina, Thomas has been a subsidiary of Daimler Trucks North America (the parent company of Freightliner) since 1998. Best known for its production of yellow school buses, Thomas produces other bus designs for a variety of usages.

Key Information

Founded in 1916 as Perley A. Thomas Car Works, the company was renamed in 1972 to better represent its primary product lines. Prior to its acquisition, the company was operated by the Perley A. Thomas family, the final major school bus manufacturer operated under family control.

Since 1936, Thomas has produced school buses in High Point, North Carolina. In addition to bus bodies, the company also produces vehicle chassis for its Saf-T-Liner/Transit Liner EFX2 and HDX2 buses. Currently, its production is concentrated on school buses and activity buses, along with their commercial derivatives.

History

[edit]

Foundation

[edit]

The oldest surviving school bus manufacturer in North America, Thomas Built Buses traces its roots to 1916. Following the closure of streetcar manufacturer Southern Car Company, Perley A. Thomas (trained as a woodworker and engineer) founded a company specializing in fireplace mantels and home furnishings.[2] In the summer of 1916, Thomas shifted from furniture to streetcar construction, as he secured a contract to enclose existing streetcars in Charlotte, North Carolina, renovating them in a car barn.[2][3]

In the summer of 1916, Thomas Car Works was founded; with a $6,000 loan ($138,459 in 2018), Thomas acquired the equipment of Southern Car Works at an auction, opening an assembly facility in a former ice manufacturing plant in High Point. During 1917, the company renovated 9 streetcars for the United States Navy in Mobile, Alabama, and for the city of Montgomery, Alabama.[2]

1918 marked several milestones for the company, as Thomas Car Works began the production of brand-new streetcars; 25 were produced. All-steel bodies were produced by the company for the first time, quickly overtaking wooden designs. At the end of 1918, the company began the construction on a larger factory, a 30-acre facility outside of High Point allowing for both construction and repair of streetcars.[2]

1920s

[edit]
Perley A. Thomas 900-Series streetcar in New Orleans (built 1923–1924)

While best known from their use in New Orleans, Perley Thomas streetcars produced during the 1920s would also be utilized by communities across the United States, including Charlotte, NC; Chicago, IL; Detroit, MI; Miami, FL; Mobile, AL; New York City; Philadelphia, PA; Washington, DC, and exported as well, with Havana, Cuba as a user.[2]

In total, Thomas Car Works produced approximately 400 streetcars from 1918 to 1930; at its peak, the company was the fourth-largest manufacturer of streetcars in the United States.[2][3]

New Orleans streetcars

[edit]

In 1921, Thomas Car Works secured its largest order for streetcars. In New Orleans, NOPSI (New Orleans Public Service, Inc.) decided to standardize their streetcar fleet upon 150 Thomas-designed streetcars, delivered from 1921 to 1924.[2][3] Unable to fill the massive order on their own, Thomas subcontracted a portion to Philadelphia-based competitor J. G. Brill (using the Thomas design).[2]

In September 1922, after Thomas delivered 25 streetcars to NOPSI, the High Point factory was destroyed by fire, causing $225,000 in damage and destroying 14 streetcars under construction.[2][3] Following the fire, Perley Thomas secured a $100,000 advance from NOPSI, rebuilding the factory and securing parts to build 55 more streetcars; 25 more were completed by the end of 1923 (bringing the total produced to 105).[2]

As of 2020, the New Orleans Regional Transit Authority operates 35 Perley Thomas 900-series streetcars in active daily use (on the St. Charles line, the oldest streetcar line in the world); the streetcars date from 1923 and 1924.

1930s

[edit]

In 1930, Thomas Car Works was reincorporated as a stock company, with Perley Thomas making his family stockholders in Perley A. Thomas Car Works, Inc.[2] For the last time, the company received an order for streetcars, producing 4 for Mobile, Alabama.[2] While rail-based streetcars offered higher capacity, for public transit, automotive-based buses grew in popularity as they offered a greater degree of routing flexibility. In a transition away from streetcars, Perley Thomas produced its first trolley bus in 1933; while still drawing power from overhead wires, a trolley bus was constructed from a bus chassis; the company ultimately built a total of only two trolley buses, for Greensboro, North Carolina.[4] For 1934, the company produced 10 transit buses for South Carolina-based Duke Power.[2]

Following the collapse of its primary source of revenue, Thomas Car Works diversified its work, expanding into automotive refinishing and construction of bus and truck bodies.[2] From 1929 to 1934, the company workforce decreased from 125 to nearly 10 (which included Perley Thomas and his 3 children).[2] Eventually, a company creditor filed for receivership, with the lack of potential buyers allowing for the survival of the company.[2]

Transition to bus construction

[edit]

In 1936, Thomas Car Works secured part of a bid to produce 500 school bus bodies for North Carolina. As the company was only financially able to acquire materials for 200 bodies, North Carolina split the bid between Thomas and Hackney Brothers.[2] Dependent on length, Thomas offered wood-bodied school buses for $195 to $225.[2] Following the completion of its second school bus bid in 1937, the company focused nearly all production on school bus bodies.[2] In what is a long tradition that continues to the present day, Thomas remains the primary supplier of school buses to North Carolina.[1]

In 1938, several major innovations were introduced by the company to its school bus design, including its first steel-bodied school bus.[2] While Perley Thomas streetcars had adopted steel construction in 1918, school bus design had slowly evolved from farm wagons, with wooden body construction continuing into the 1930s. Although not the first to construct an all-steel body, Thomas introduced one-piece roof bows, internal roll bars welded to each side of the floor/frame structure.[2] While the design has been updated for added strength, the one-piece roof bow is in use in all school buses manufactured in North America today. In another innovation, Thomas introduced an outward-opening entry door, designed to aid egress in emergency evacuation situations.[2]

1940s

[edit]

In 1940, day-to-day operation of Thomas Car Works was turned over from Perley Thomas (who remained company president) to his three children. John W. Thomas managed company operations along with sales, along with James Thomas handling the High Point factory.[2] Following the outbreak of World War II, as with its competitors, Thomas bus production was shifted towards the armed forces. In a contract shared with Ward Body Works, Thomas also produced various bodies for the GMC CCKW truck.[2]

While the war had brought school bus production to a halt, the High Point factory remained utilized in civilian capacity. To supplement its armed forces production, Thomas Car Works was put to use by refurbishing streetcars. As rationing had placed increased demands on public transportation, the upkeep of existing equipment was considered a priority.[2]

Following World War II, with a rise in student populations, Thomas Car Works began to expand its sales market beyond the South, opening dealerships across the eastern half of the United States.[2] To better weatherproof its entry door, the company developed a reinforced rubber-covered door hinge; the rubber also covered the gap between the two door panels as they closed.[2]

After World War II, a third generation of the family joined the company, with John W. Thomas Jr. and Perley (Pat) Thomas II, with the former becoming director of sales and the latter taking over control of government contracts.[2]

1950s

[edit]

During the decade, Thomas Car Works began exports of its product lines, establishing satellite facilities in Ecuador and Peru. From North Carolina, bodies were shipped to South America in CKD form for final assembly on locally sourced chassis.[2]

In 1957, the Thomas Saf-T-Liner name made its first appearance, denoting updated bus bodies (with an enlarged two-piece windshield).[2] Used full-time by 1972, the name remains in use for all full-size Thomas buses over 60 years later.

Company founder Perley Thomas died in 1958 at the age of 84; at the time of his death, Thomas retained his title of company president and also actively served as a design consultant.[2][5]

1960s

[edit]
1961 Thomas school bus on an International Harvester chassis
Late-1960s Thomas Saf-T-Liner body on GMC H6500 chassis (rare) in New York as a farm bus

In 1962, Thomas Car Works officially expanded its production beyond High Point as Thomas Built Buses of Canada, Ltd. was established in Woodstock, Ontario.[2] At the time, the company became the third-largest producer of school buses in the United States.[2]

To demonstrate the strength of its internal roof bows, Thomas stacked a full-size school bus on the roof of another (using a crane) in 1964;[2] the company has subsequently repeated the demonstration several times using more recent product lines.

For 1967, to reduce blind spots in front of the bus, Thomas developed a convex blind-spot mirror.[2] Initially mandated in North Carolina, the device (allowing a 150-degree field of vision directly in front of the bus) would be adopted by 16 other states in only two years.[2] In various forms, blind-spot mirrors are currently required on all school buses in North America.

1970s

[edit]
1977–1983 Thomas Saf-T-Liner Conventional on Chevrolet chassis in North Carolina (retired)

In the early 1970s, Thomas underwent a number of major transitions in company leadership and market positioning. Company president John W. Thomas died in 1972, giving leadership to his brother James Thomas, who retired within a year. A third generation of the Thomas family assumed control of the company leadership, with John Thomas Jr. (President) and Perley Thomas II (VP, international operations).[2]

As Thomas Car Works had ended its involvement with streetcars since World War II, the new generation of company leaders chose a new name for the company tied closer to its current product lines; in 1972, Perley A. Thomas Car Works was renamed Thomas Built Buses, Inc (used in its emblems and marketing material since the 1950s).[2][1]

Expanded school buses

[edit]

Since producing its first school bus in 1936, virtually all Thomas school bus bodies had been produced in the "conventional" style: a body mated to a cowled truck chassis.[citation needed] While the design was the most popular configuration, the transit-style configuration allowed for a higher passenger capacity (up to 90 passengers). In the early 1970s, Thomas developed the Saf-T-Liner ER (Engine Rear) as an alternative to the Blue Bird All American. In line with other body manufacturers (Carpenter, Superior, Ward, and Wayne), Thomas was dependent on a second-party manufacturer for rear-engine chassis (using Ford, Dodge, GMC, International Harvester and Volvo).

In the early 1970s Thomas Built Buses introduced the first of its "Mighty Mite" series of buses and were the smallest conventional bus ever produced by Thomas. Most were built on Dodge D300 chassis but when production of this series ended at the main plant in High Point, NC, production was moved to Woodstock, Ontario and the Canadian built Mighty Mites used modified International Loadstar chassis.

1971 Thomas Mighty Mite on Dodge S-Series chassis.

For 1972, the Saf-T-Liner body underwent a major redesign. Along with extending the rub rails completely around the body, the front and rear roof caps were flattened (to accommodate 8-lamp warning systems), and the windshield was enlarged. Following the addition of safety upgrades to comply with safety mandates in 1977, the Saf-T-Liner body saw use in the Conventional through the end of 2006; in modified form, it remains in use with the EFX and HDX (and resized to fit the Minotour). At the smaller end of the size scale, the Saf-T-Liner body was resized to produce the Mighty Mite, a narrow-body school bus on a shorter-wheelbase conventional chassis.[6]

In 1977, Thomas made a major change to the production of the Saf-T-Liner ER. Coinciding with a design update, Thomas introduced a company-sourced chassis, along with the front-engine Saf-T-Liner EF. With the introduction of the EF, Thomas became the first school bus manufacturer to produce its own chassis for both front and rear-engine school buses, ahead of Blue Bird by a decade (California manufacturers Crown Coach and Gillig Corporation had not produced a front-engine school bus since before World War II). As a competitor to the Blue Bird Mini Bird and Carpenter Cadet, Thomas reintroduced the Mighty Mite as a Type B bus, a school bus body paired with a stripped chassis.

1980s

[edit]
Thomas Saf-T-Liner Conventional with late-1980s Ford B700 chassis (Quebec)

The late 1970s and early 1980s was a period of struggle for all school bus manufacturers. Coupled with the slow economy, manufacturers could no longer count on the factor that had driven school bus sales for the past two decades: the entirety of the baby-boom generation had finished school; it would be years before student populations would create sufficient demand again. During this time, a number of manufacturers either encountered financial difficulty or closed their doors altogether.

At the beginning of the decade, Thomas introduced a new logo, displayed on the roofline of its buses; a "T-bus" logo replaced the previous scripted "Thomas Built Buses" company logo (still attached elsewhere to the body).

To better secure the future of the company, the Thomas family sought to raise capital for Thomas Built Buses, leading the company board to bring in the Odyssey Group investment firm to oversee the process.[2] In return, Odyssey Group received a stake in the company (remaining under full family control).[2]

In the early 1980s, Thomas launched a diversification of its product line, expanding its presence in the transit bus segment.[5] Derived from the Saf-T-Liner, the Transit Liner was developed for commercial use. In 1982, the CL960 "Citiliner" was introduced as a dedicated transit bus;[7] while sharing its underpinnings with the Saf-T-Liner ER, the two-door CitiLiner was rebodied (with a sloped windshield). Sharing its body with the CL960, the Chartour was developed for charter use, using a single entry door.[8]

Product innovations

[edit]
1995 Thomas Vista (International 3600) in Colorado with wheelchair lift and flat floor

Following the mid-1970s launches of the Wayne Busette and Blue Bird Micro Bird, Thomas would launch its own cutaway-chassis school bus, the Thomas Minotour, in 1980. Alongside the small Minotour, Thomas introduced the WestCoastER, a heavy-duty variant of the Saf-T-Liner ER marketed against Crown Supercoach and Gillig Phantom school buses. Sold only in 84 and 90-passenger configurations, the WestCoastER used heavier-duty driveline and suspension components; tandem rear axles were offered as an option.

In 1989, Thomas introduced a second conventional-style bus to its model line, launching the Thomas Vista school bus. To optimize forward sightlines for drivers, the layout of the driver's compartment and forward chassis were redesigned. Along with a shorter hood and redesigned windshield, the engine and front axle were repositioned. In contrast to a standard conventional bus, the driver of the Vista sat beside the engine (rather than behind it).

1990s

[edit]
2001 Thomas TL960 of LACMTA

In 1991, the Saf-T-Liner transit-style buses saw their first redesign since 1977. The ER and WestCoastER were given a much larger windshield, redesigned driver's compartment, and saw the introduction of several new diesel engines. To better compete with the Blue Bird TC/2000 and Ward Senator (which became the AmTran Genesis), Thomas replaced the Saf-T-Liner EF with the All Star, using an Oshkosh-produced chassis. The Thomas Vista continued production, shifting chassis in 1991 from General Motors to a variant of Navistar chassis shared with the Saf-T-Liner Conventional.

In 1992, the fourth generation of the Thomas family took over daily operations of the company (becoming the first family-owned school bus company to do so).[2]

During the mid-1990s, the company began development of environmentally cleaner buses, with compressed natural gas (CNG) school buses entering production in 1993; several battery-electric school buses were produced in 1994 as prototype vehicles.[2]

By 1996, Thomas had become the largest school bus manufacturer in the United States (by market share).[2] To keep up with added demand, the company opened a third factory in Monterrey, Mexico. As a design change, the "T-bus" roof emblem (used since the early 1980s) was replaced by a scripted Thomas Built Buses emblem (its predecessor).

During the later 1990s, Thomas Built Buses would undergo a number of significant changes, with some that have changed the future of school bus manufacturing. For the 1997 model year, Freightliner introduced the Freightliner FS-65 school bus chassis.[9][10] Derived from the Freightliner FL60/FL70 medium-duty trucks introduced in 1995, the FS-65 chassis was paired with the Saf-T-Liner Conventional body, after several modifications (distinguished by the addition of a 4-piece windshield).

Transit expansion

[edit]

During the 1990s, Thomas modernized and expanded its product range within the transit segment. Alongside the Chartour and CL960/Citiliner, Thomas marketed Transit Liners, commercial derivatives of the Saf-T-Liner school buses, along with commercial versions of the Minotour and Vista.[11] A dedicated transit bus derived from the Saf-T-Liner ER, the TL960 was a two-door bus that offered an integrated wheelchair ramp as an option.[3]

In 1999, Thomas entered a joint venture with British bus manufacturer Dennis to import the Dennis Dart SLF (in CKD form).[2][12] Following assembly by Thomas in North Carolina;[13] while badged as Thomas vehicles (the Thomas Dennis SLF200), distribution of the low-floor buses was undertaken by Orion Bus (itself becoming a Daimler subsidiary in 2000).[2][14]

Company acquisition

[edit]
Thomas Saf-T-Liner FS-65 (North Carolina activity bus)

Into the late 1990s, Thomas Built Buses remained a family-owned company, controlled by the fourth generation of the Thomas family and the Odyssey Group.[2] Following the departure of Wayne Wheeled Vehicles from the manufacturing segment, Thomas became the largest manufacturer, holding a 34% market share in 1996.[2] The same year, the Thomas family sold a majority stake of the company to the Berkshire Partners equity firm.[15]

Freightliner entered school bus manufacturing as a chassis producer in May 1996,[16] unveiling the Freightliner FS-65 (derived from its FL60/FL70 Business Class medium-duty truck); developed in cooperation with Thomas,[2][16] the first production Freightliner-chassis buses were produced at the beginning of 1997.[10] The product launch marked the first completely new school bus chassis since 1980, with Freightliner becoming the first new cowled-chassis manufacturer since the 1977 withdrawal of Dodge.

Following its collaboration with Thomas in developing the FS-65 chassis, in October 1998, Freightliner acquired Thomas Built Buses in its entirety from the Thomas family and the Berkshire, retaining company president John W. Thomas III.[2][17] The largest school bus manufacturer in North America at the time, Thomas Built Buses was the last major manufacturer operating under family control. At the time, Freightliner was undergoing a series of company acquisitions to diversify its product range beyond highway trucks. Along with acquiring the rights to the Ford heavy-truck line (and Ford Cargo) in 1997 (continued as Sterling Trucks), Freightliner acquired Thomas alongside the chassis production of Oshkosh Corporation (1995), American LaFrance (1996).

For school bus manufacturers, the 1990s marked a period of association between major body and chassis manufacturers. In 1991, Navistar began its purchase of AmTran (completed in 1995); a year later, Blue Bird entered in a supply agreement with General Motors for conventional bus chassis. 1998 marked both the purchase of Thomas by Freightliner and the sale of Carpenter to Spartan Motors (its front/rear-engine chassis supplier).

At the end of the 1990s, several changes made to the Thomas product line were related to its purchase by Freightliner. At the end of 1998 production, Navistar ended its chassis production for the Vista; as the Vista body was developed solely for its chassis, Thomas discontinued the model line. While Freightliner did not purchase the Ford medium-duty truck range or the school bus chassis derived from it, Ford ended production of the latter after 1998. Consequently, from 1999 onward, the Saf-T-Liner Conventional was limited to Navistar or Freightliner chassis (along with AmTran/Ward, Carpenter, and Wayne, the last General Motors chassis for a Thomas bus was produced in 1991).

2000s

[edit]
2003 Thomas Saf-T-Liner ER powered by CNG, has the rear end of a HDX.

In the school bus manufacturing segment, the beginning of the 2000s marked a period of uncertainty. In 2001, following the closure of Carpenter, the number of body manufacturers had declined from seven to three in ten years; AmTran would rebrand itself (twice, in less than two years). The acquisition of Thomas by Freightliner brought financial stability to the company (something not initially afforded to the Blue Bird Corporation).

In the early 2000s, Thomas restructured its manufacturing footprint, centering it around its High Point headquarters. Following the closure of the Monterrey facility in the late 1990s, the company opened a separate facility in High Point for Minotour assembly in 1999;[5] in 2000, a facility was opened to produce Thomas Dennis low-floor buses in Jamestown, North Carolina.[5][13] Thomas Built Buses of Canada in Woodstock, Ontario, was closed in late 2001 (as part of a Freightliner restructuring),[18] with Thomas opening a third school bus assembly facility High Point in 2004.[19]

In 2002, John W. Thomas III retired, becoming the final family member to manage the firm; serving as president since 1992, Thomas remained with the company as a consultant.[15] He was succeeded by John O'Leary, a financially educated manager in charge of the turnaround of parent company Freightliner.[15]

During the 2000s, Thomas began to wind down its presence in the transit bus segment. While the Thomas Dennis SLF200 found buyers, the product line struggled to gain a foothold against established transit buses; after 2002, the Thomas Dennis joint venture was reorganized by Daimler (effectively replacing Thomas with distributor Orion) and the SLF200 was discontinued when Dennis' successor Transbus International withdrew from the venture.[14] The Thomas-designed TL960 (which replaced the aging Chartour/CL960) was discontinued in 2002, replacing dedicated transit buses with school bus derivatives as Thomas consolidated commercial production to the Transit Liner EF/ER.

In 2005, company founder Perley Thomas became one of the first inductees (posthumously) of the North Carolina Transportation Hall of Fame in Raleigh, North Carolina.[20] In 2007, the North Carolina Transportation Museum received the donation of a 1940 Thomas Car Works school bus from Thomas Built Buses.[20]

Following the 2004 introduction of the Saf-T-Liner C2, Thomas produced the model line along its Saf-T-Liner Conventional predecessor. After nearly 35 years of production of the Saf-T-Liner Conventional body; the 62,764th and final example on the FS-65 chassis was produced on December 13, 2006.[21]

New-generation buses

[edit]
Thomas Saf-T-Liner C2 school bus in Mississippi

At the beginning of the 2000s, Thomas began to introduce its most extensive updates to its product lines since the 1970s. In 2000, the Saf-T-Liner HD was introduced (combining the Saf-T-Liner ER, WestCoastER, and the MVP ER). Distinguished by its large mirror housings (integrating sideview, convex, and crossview mirrors into a single assembly), the HD also visibly shared several components from Freightliner, including its instrument cluster and headlamps. In 2002, Thomas renamed the HD the Saf-T-Liner HDX. For 2003, Freightliner became the sole chassis supplier for the Saf-T-Liner Conventional, with all Conventionals becoming Saf-T-Liner FS-65s.

Following the 2002 replacement of the FL-series Business Class with the Business Class M2, development was underway on a new-generation Thomas Saf-T-Liner conventional school bus. In 2004, the Thomas Saf-T-Liner C2 made its debut, marking the first completely new bus body from Thomas since 1972.[22] In a shift from industry precedent, both the Thomas body and Freightliner chassis were designed together as a common unit (allowing the use of the dashboard in nearly its entirety); as a drawback, the pairing negated the use of the Freightliner C2 chassis by other body builders. In contrast to the Saf-T-Liner Conventional, the C2 is designed with a larger, sloped windshield, larger windows and exits, and different body construction.

For 2009, Thomas launched a second model line of small buses. Named the Thomas MyBus, the model line is geared towards the MFSAB (activity bus) segment.[23] Sharing its internal structure with the Minotour, the non-yellow MyBus is designed for applications without any need for traffic control.[24]

2010s

[edit]
Thomas Saf-T-Liner HDX in Maine; bus is equipped with CNG fuel system

In 2010, John O'Leary was succeeded as company president by Kelley Platt; the first female leader of a major school bus manufacturer, Platt served as manager of treasury services during the Freightliner acquisition of Thomas Built Buses.[25]

In the fall of 2011, Thomas unveiled the Saf-T-Liner EFX, its first all-new front-engine bus since 1994. Production of the EFX began in the spring of 2012. Using similar design features as the Saf-T-Liner HDX (its windshield and upper bodywork), the EFX also utilized a center-mounted Freightliner instrument panel.

During the early 2010s, Thomas expanded its environmentally friendly product line. The Saf-T-Liner C2e hybrid diesel-electric school bus (introduced in 2007) met with little success, leading to its withdrawal in 2013; instead, the company invested in its alternative-fuel product lines. Having offered compressed natural gas (CNG) since 1993 in the Saf-T-Liner ER, the Saf-T-Liner C2 gained propane and CNG offerings (in 2014 and 2016, respectively). Alternative fuels became available on the Minotour (coinciding with chassis specification).

In 2016, Thomas Built Buses marked 100 years since the founding of Perley Thomas Car Works, becoming the first current bus body manufacturer to reach 100 years of production in North America.

In 2018, Thomas Built Buses would introduce Detroit Diesel engines into their school buses, marking the first time that Detroit Diesel engines have been used in school buses since the late 80s.[26]

In late 2019, Thomas entered into a joint venture with Trans Tech to jointly develop a small school bus. Named the Minotrek,[27][28] The Ford Transit cutaway-chassis school bus is designed with an aerodynamically enhanced body to optimize fuel economy.[28]

Environmental stewardship

[edit]
2018 Thomas Saf-T-Liner C2 Jouley (prototype all-electric bus)

In 2011, the High Point facilities of Thomas Built Buses achieved Zero-Waste-to-Landfill status in its vehicle production.[29] A year later, the company was designated a North Carolina Environmental Steward, citing its superior environmental performance, commitment to continued reduction of its environmental impact, and demonstrated commitment to exceed compliance regulations.[citation needed]

In late 2017, in line with each major school bus manufacturer, Thomas unveiled a fully electric school bus prototype. The Saf-T-Liner C2 Jouley (deriving its name from the unit of energy) entered full production during 2020.[30][31]

2020-present

[edit]

In July 2024, Thomas Built Buses revamped the model into the Saf-T-Liner HDX2, which takes design cues from the Type C Saf-T-Liner C2.[32] In March 2025, Thomas Built Buses announced the new Saf-T-Liner EFX2 which, like the HDX2, takes design cues from the Saf-T-Liner C2. Both newly introduced buses will be produced in the same Archdale, North Carolina plant as the C2. This marks the full transition of Type-D production to the Saf-T-Liner C2 Facility (now the Saf-T-Liner Facility).

In October 2025, Thomas Built Buses introduced the Saf-T-Liner eHDX2 "Wattson", an electric version of the HDX2.[33]

Products

[edit]

Thomas Built Buses is a manufacturer of school bus bodies in cutaway van (Minotour), conventional (early Mighty-Mite series) (Saf-T-Liner C2), and transit-style (Saf-T-Liner EFX2/HDX2) configurations. Other bodies produced by the company include derivatives of its school bus designs (activity buses and child-care buses) along with buses for commercial use; some vehicles are intended for specialty use.

Alongside diesel-fueled vehicles, dependent on product line, Thomas buses are also offered with alternative-fuel options, including propane, CNG, gasoline, and fully electric powertrains.

School buses

[edit]
Current product line
Model Name Thomas Minotour MyBus Thomas Saf-T-Liner C2 Thomas Saf-T-Liner (EFX2, HDX2)
Photo
Year Introduced
  • Minotour: 1980
  • MyBus: 2009
2004
  • EFX: 2012 (as Saf-T-Liner EFX) 2025 (as Saf-T Liner EFX2)
  • HDX: 2000 (as Saf-T-Liner HD) 2002 (as Saf-T-Liner HDX) 2024 (as Saf-T Liner HDX2)
Assembly High Point, North Carolina
Configuration Type A (cutaway)
  • single rear wheel, dual rear wheel (Minotour, MyBus)
Type C (conventional) Type D (transit-style)
Chassis Manufacturer Ford Motor Company

General Motors

Daimler Trucks North America LLC (Freightliner)
Thomas Built Buses
  • Front-engine Type D chassis
  • Rear-engine Type D chassis
Fuel type(s)

Minotour

  • Gasoline

MyBus

  • Gasoline
  • Compressed Natural Gas (CNG)
  • Diesel
  • Propane
  • Electric

EFX2

  • Diesel

HDX2

  • Diesel
  • Electric
Passenger Capacity 14-30 up to 81 up to 90
Other notes

Minotour

  • Produced as school bus and MFSAB

MyBus

  • Based on Minotour, produced only as MFSAB on Chevrolet/GMC chassis
  • Produced as school bus, commercial bus, and MFSAB/activity bus
  • Uses Freightliner C2 chassis, derived from Freightliner M2 106 Business Class medium-duty truck
  • Replaces both Saf-T-Liner Conventional and Saf-T-Liner FS-65
  • Produced as diesel-electric hybrid (C2e) from 2007 to 2013
  • Propane version released in 2013
  • CNG Version released in 2016
  • Electric prototype called the "Jouley" shown in 2017; intended for 2019 production

EFX2

  • Produced as school bus, commercial bus, and MFSAB/activity bus
  • Replaced Thomas Saf-T-Liner EF in 2012
  • Shares some front bodywork and windshield with HDX.

HDX2

  • Produced as school bus, commercial bus, and MFSAB/activity bus
  • Introduced in 2000 as the Saf-T-Liner HD; replaced the Saf-T-Liner ER and Saf-T-Liner MVP ER.
  • Distinguished by large front mirror units, which mount the side-view, wide-angle, and cross-view mirrors into a single unit.
Former product lines
Model name Production Vehicle type Chassis Notes
Mighty Mite

1977?–1994? Type B (integrated) General Motors
  • Chevrolet P-30
  • Also the name of the lowest-capacity versions of Thomas Conventionals in the 1970s.
  • Also used for base for para-transit buses in Toronto.
Saf-T-Liner Conventional

1972–2002 Type C (conventional) Chrysler Corporation
  • Dodge D-300 (to 1977)

Ford Motor Company

General Motors

International Harvester
Navistar International

  • Introduced in 1972 when the company renamed "Thomas Built Buses".
  • Distinguished by windshield wipers mounted above windshield (2-piece flat glass)
  • Discontinued after the 2003 model year by the end of 2002.
Saf-T-Liner FS-65

1997–2006 Freightliner (Daimler)
  • Saf-T-Liner FS-65 is one product of the Freightliner purchase of Thomas in 1998.
  • All FS-65 chassis wore Thomas bodies after 2002.
  • Saf-T-Liner FS-65 body has a 4-piece windshield
Vista

1989–1998 Type C (conventional)
  • semi-forward control
General Motors (1989–1991)
  • Chevrolet/GMC B6 (modified)

Navistar International (1991–1998)

  • To aid forward visibility, the Vista mounted the driver's seat alongside the engine rather than behind it, similar to a Type D bus.
  • Produced on a Thomas-badged Chevrolet/GMC chassis from 1989 to 1991 and an International chassis from 1991 to 1998.
  • 1994 update gained additional windshield and side windshield glass.
Saf-T-Liner EF/ER

Saf-T-Liner EF
1972–1990, 2006–2012

Saf-T-Liner ER
1972–2002

Type D (transit-style)
  • front engine
  • rear engine
Various (to 1977)
Thomas Built Buses
Saf-T-Liner EF
  • Introduced in 1972.
  • Replaced by All-Star in 1991.
  • Name reintroduced in 2006 as part of MVP redesign, replaced by EFX.

Saf-T-Liner ER

  • Introduced in 1972.
  • Fully discontinued in 2002.
  • Replaced by Saf-T-Liner HDX for 2003.

WestCoastER

  • Heavy-Duty derivative of Saf-T-Liner ER sold to West Coast customers.
  • Built with 84 and 90 passenger bodies; tandem rear axles were an option on 90-passenger version.
Saf-T-Liner MVP EF/ER, All-Star

All-Star
1991–1994

Saf-T-Liner MVP EF
1994–2006
Saf-T-Liner MVP ER
1995–2000

All-Star
  • Oshkosh Corporation

Saf-T-Liner MVP EF/ER

  • Thomas Built Buses
All-Star
  • Front-engine chassis built by Oshkosh Corporation; built from 1991 to 1994 as a competitor to Blue Bird TC/2000.
  • Distinguished from MVP EF by having Thomas emblem above grille (rather than centered).
  • Distinguished by previous Saf-T-Liner EF by much larger windshield and dual headlights (rather than four)

Saf-T-Liner MVP EF

  • Replaced All-Star in 1994; built on Thomas chassis.
  • MVP= Maneuverability, Visibility, and Protection.
  • Changed to Saf-T-Liner EF for 2007 as part of an update and replaced by EFX in 2012.

Saf-T-Liner MVP ER

  • Built on Thomas chassis
  • MVP= Maneuverability, Visibility, and Protection.
  • Replaced by Saf-T-Liner HD (later HDX) for 2001.

Other buses

[edit]

Thomas sold commercial derivatives of the Minotour, Conventional, Vista, along with the following:[34]

Thomas/Dennis SLF200

Company timeline

[edit]
Thomas Built Buses, Inc. timeline (1972–present)
Bus Type 1970s 1980s 1990s 2000s 2010s 2020s
'72 '73 '74 '75 '76 '77 '78 '79 '80 '81 '82 '83 '84 '85 '86 '87 '88 '89 '90 '91 '92 '93 '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11 '12 '13 '14 '15 '16 '17 '18 '19 '20 '21 '22 '23 '24 '25 '26
Type A Minotour
MyBus
Type B Mighty Mite
Type C Saf-T-Liner Conventional
FS-65
C2
Vista Vista
Type D Saf-T-Liner EF/ER ER
All Star EF MVP EF EF EFX EFX2
MVP ER
HD HDX HDX2
Transit buses CL960 "CitiLiner"
Chartour
TL960 "TransLiner"
SLF200

See also

[edit]

References

[edit]
[edit]
Revisions and contributorsEdit on WikipediaRead on Wikipedia
from Grokipedia
Thomas Built Buses is an American manufacturer of school buses and related commercial vehicles, headquartered in , and recognized as one of the leading producers of Type C and Type D es in . Founded in 1916 by Perley A. Thomas as the Perley A. Thomas Car Works, the company initially focused on building streetcars amid the economic disruptions of , before transitioning to school bus production in with innovations like all-steel construction and rear safety doors that helped secure its first state contracts. Renamed Thomas Built Buses in 1972 to reflect its core product line, the company introduced landmark models such as the Saf-T-Liner transit-style bus in 1977 and has since pioneered advancements including hybrid-electric (2007), all-electric (2017), and alternative-fuel options like propane and CNG-powered buses. Over its more than century-long history, Thomas Built Buses has evolved from a family-owned operation—reaching fourth-generation leadership by 1992—to a of Freightliner LLC (part of ) since 1998, emphasizing safety, sustainability, and innovation in pupil transportation. Key products include the Saf-T-Liner C2 (a forward-engine Type C bus launched in 2004), the Saf-T-Liner HDX (a rear-engine Type D model), the smaller Minotour Type A bus, and the Jouley and Wattson all-electric school buses, with the company achieving zero-waste-to-landfill certification in 2011. As of September 2025, Thomas Built Buses operates as part of the newly formed Specialty Vehicles division alongside Freightliner Custom Chassis Corporation, employing approximately 1,900 people and serving school districts, charter operators, and commercial fleets across the and with a commitment to durable, customizable, and eco-friendly transport solutions.

Overview

Company profile

Thomas Built Buses, founded in 1916, is headquartered in , where it serves as a prominent manufacturer of school buses in . As a of LLC (DTNA), the company has integrated operations with Freightliner Custom Chassis Corporation under the Daimler Truck Specialty Vehicles division following a 2025 consolidation, enhancing its chassis and vehicle production synergies. With approximately 1,900 employees as of 2025, Thomas Built Buses maintains an annual production capacity exceeding 15,000 buses across its facilities. The company holds about a 30% market share in the U.S. segment, with one in three school buses on the road being a Thomas Built model. Thomas Built Buses emphasizes safety, durability, and innovation in its vehicle designs, prioritizing features that protect passengers and support long-term reliability for school transportation fleets.

Ownership and leadership

Thomas Built Buses traces its origins to 1916, when Perley A. Thomas established the company as Perley A. Thomas Car Works in , under private family ownership that persisted through the economic challenges of the . In 1930, amid the onset of the Depression, the firm incorporated as Perley A. Thomas Car Works, Inc., marking a structural shift while Thomas retained control as the principal owner and leader. This family stewardship continued uninterrupted until the late , with Perley A. Thomas serving as president until his death in 1958, after which family members maintained oversight. The company's ownership transitioned in 1998 when it was acquired by Freightliner LLC, a division of DaimlerChrysler, becoming a wholly owned subsidiary and ending generations of independent family operation. This acquisition integrated Thomas Built Buses into the broader Daimler portfolio, leveraging Freightliner's resources for expansion in the school bus sector. By 2009, following Daimler's corporate restructuring, Thomas Built Buses achieved full operational alignment as a subsidiary of Daimler Trucks North America LLC (DTNA), the North American arm of the global Daimler Truck group. In September 2025, DTNA consolidated Thomas Built Buses with Freightliner Custom Chassis Corporation (FCCC) to form Daimler Truck Specialty Vehicles, a unified entity aimed at enhancing efficiency and innovation in specialty vehicle production. This reorganization positioned Thomas Built Buses within a streamlined structure under DTNA, with shared resources for chassis and bus manufacturing. Leadership at Thomas Built Buses has evolved alongside its ownership. Early guidance came from founder Perley A. Thomas, who directed the shift from streetcar production to school buses in . Post-acquisition, executive roles have been filled by Daimler-affiliated professionals, with the company currently led by T.J. Reed as president and CEO, appointed in September 2024 to oversee both Thomas Built Buses and FCCC prior to the 2025 consolidation. Reed now heads Specialty Vehicles, reporting to DTNA's senior executives, including board-level oversight from Daimler Truck AG.

History

Founding and early development (1916–1930s)

Perley A. Thomas, a Canadian-born engineer and former chief engineer at the Southern Car Company, founded Perley A. Thomas Car Works in 1916 in , following the closure of his previous employer due to World War I-related economic pressures. Initially focused on renovating and constructing streetcar bodies, the company capitalized on Thomas's expertise in wooden and steel-frame designs, drawing from High Point's established furniture and industry to employ local craftsmen. The firm's early operations involved overhauling streetcars for utilities like Southern Public Utilities in Charlotte, with its first new construction order coming in 1917 for four streetcars destined for Winston-Salem. During the , the company expanded significantly amid growing demand for urban transit, securing major contracts that solidified its reputation as a key streetcar builder. A pivotal deal came with New Orleans Public Service Inc., for which Thomas produced 150 streetcars, including the iconic 900-series arch-roof models delivered between 1922 and 1924, designed for double-ended operation on the city's expanding lines. These vehicles, noted for their durable construction and adaptation to local needs, represented a substantial portion of the company's output and helped sustain operations through a period of industry growth, with Thomas streetcars also serving cities like . By the late , the firm had grown to employ over 125 workers and was producing streetcars for transit systems across , leveraging Thomas's innovations in safety and efficiency. The onset of the in brought severe economic challenges, drastically reducing streetcar orders as utilities retrenched and automobile ownership rose, signaling the broader decline of rail-based urban transit. Incorporated as Perley A. Thomas Car Works, Inc. in 1930, the company adapted by diversifying into bus manufacturing to survive the shifting market. In 1934, it delivered its first bus order—10 wooden-bodied transit buses customized for Duke Power Company in , marking an initial pivot from streetcars. This was followed in 1936 by the production of 200 all-steel bodies for operators, featuring innovative outward-swinging rear safety doors to enhance passenger evacuation—a design that set Thomas apart and fully transitioned the firm away from streetcar production by year's end. These early buses were tailored for local school districts and utilities, emphasizing durability and safety amid the era's regulatory changes.

Wartime production and post-war growth (1940s–1960s)

During , Perley A. Thomas Car Works shifted its production from civilian buses to military vehicle components under government contracts, contributing significantly to the war effort. The company manufactured metal pontoons for engineers to construct temporary bridges over streams and rivers, as well as ambulance bodies for the GMC CCKW 2½-ton 6×6 and troop transport bodies for the GMC 1 ½-ton 4×4 . These efforts included producing over 1,000 bodies at a rate of 15 units per day, alongside building military buses and repairing vehicles, which earned the firm a U.S. citation for its contributions. School bus production was suspended during this period, with the final pre-war order fulfilled for the U.S. Marine Corps at Camp Lejeune. Additionally, a Thomas ST6 model was adapted to serve as General Patton's personal quarters. Following the war's end in , Perley A. Thomas Car Works refocused on civilian bus production, resuming and expanding its line that had originated in 1936. By the late , the company was building all-steel bodies on various , including , to meet growing demand for safe student transportation across the . Production ramped up quickly, reaching 6 to 7 buses per day by 1949 with a workforce of 350 employees, emphasizing durable construction and safety features like rear exit doors. This emphasis helped the firm secure contracts in over 30 states, including a major order for 650 buses in through a with Hackney Bros. Body Co. In the , the company experienced substantial growth in commercial transit buses, producing specialized vehicles for , universities, and urban fleets alongside its core offerings. This expansion was supported by establishing a robust dealer network across the U.S. South, with distributorships in states such as , , , , and others by , facilitating wider . Innovations like the Saf-T-Vue panoramic , introduced in the late , enhanced visibility and safety, solidifying the company's reputation. The marked further diversification into medium-duty buses, building on the transit models to serve broader commercial needs while maintaining a national profile as a leading manufacturer under the leadership of Perley Thomas's children and grandchildren. Annual production scaled steadily, reaching approximately 1,000 units by 1969 as demand grew for reliable, all-steel vehicles in both educational and transit sectors. This period of scaling positioned the company for continued dominance in the bus industry.

Expansion into school buses (1970s–1980s)

In the early 1970s, Thomas Built Buses strategically shifted its focus toward school bus manufacturing, formalizing this direction with a corporate reorganization and renaming to Thomas Built Buses, Inc. in 1972. This pivot built on the company's prior experience in bus bodies while emphasizing purpose-built school vehicles. A key milestone came in 1973 with the introduction of the Saf-T-Liner, a transit-style school bus featuring enhanced safety elements such as improved visibility through a sloping front design and initial padded seating to protect passengers. By 1977, the company launched its first proprietary bus chassis, enabling full production of the Saf-T-Liner and expanding its school bus lineup to meet growing demand from educational districts. The 1980s marked further innovation in school bus design, with Thomas Built Buses introducing the Type C forward-engine model in 1982, which offered greater maneuverability and accessibility for urban routes compared to rear-engine predecessors. This period also saw the widespread adoption of diesel engines in school buses, starting in the early , which provided superior , reliability, and —lasting 15-20 years under heavy use—while aligning with emerging environmental standards. These advancements allowed Thomas to refine its offerings for efficiency without compromising the durability essential for daily student transport. Market expansion accelerated during this era, positioning Thomas Built Buses as one of the leading U.S. school bus manufacturers. Production scaled rapidly, reaching over 4,000 units annually by 1973 and surpassing 6,000 school buses per year by 1978 at its expanded facility. By 1989, annual sales exceeded 5,000 units, reflecting strong adoption by school districts nationwide and internationally through facilities in and beyond. This growth solidified the company's reputation for reliable, high-volume supply in a consolidating industry. Throughout the 1970s and 1980s, Thomas Built Buses actively responded to evolving federal safety regulations, particularly the (FMVSS) effective from 1977, which mandated compartmentalization for occupant protection in crashes. This involved integrating high-backed, padded seats with energy-absorbing structures to create protective zones around passengers, eliminating the need for lap belts in large buses while enhancing crash resilience. Compliance with FMVSS Nos. 220 (rollover protection), 221 (school bus body joint strength), and (passenger crash protection) raised production costs by $1,200–$1,500 per unit but established Thomas's buses as exemplars of safety innovation.

Acquisitions and product diversification (1990s–2000s)

In the late 1990s, Thomas Built Buses underwent a pivotal acquisition when Freightliner LLC, a subsidiary of DaimlerChrysler, purchased the company from the Odyssey Group in 1998, integrating it into a larger network of truck and operations. This move provided access to Freightliner's chassis technologies and Daimler's engineering resources, enabling enhanced product development and efficiencies during the subsequent decade. The acquisition spurred diversification beyond traditional school buses, particularly in transit applications. In 1999, Thomas formed a joint venture with Mayflower Corporation to produce super low-floor (SLF) transit buses, leading to the opening of a dedicated facility in Jamestown, North Carolina, in 2000 for manufacturing these models aimed at urban accessibility needs. Concurrently, the company expanded its school bus portfolio by adopting the Freightliner FS-65 chassis for the Saf-T-Liner FS-65 conventional model starting in 1997, which offered improved durability and was produced until its retirement in 2007. Into the 2000s, integration with Daimler facilitated the launch of next-generation school buses, including the Saf-T-Liner HDX in 2002, a Type D transit-style model that replaced the earlier Saf-T-Liner ER and HD variants with heavier-duty construction for higher passenger capacity and rugged performance. This period also saw diversification into Type A cutaway buses, with continued production of the Minotour line—supported by a new High Point plant opened in 1999—and the introduction of the MyBus in 2009, a specialized Type A model tailored for childcare, activity centers, and service organizations. Enhanced chassis options, including those incorporating components from the Daimler lineup, allowed for greater customization in both Type A and Type D configurations. A key focus in the 2000s was on ergonomics and accessibility to meet evolving regulatory and user demands. The Saf-T-Liner C2, introduced in 2004 and built on an integrated Freightliner chassis, featured a large undivided windshield for 30% improved driver visibility, a 55-degree steering angle for better maneuverability, and a modernized driver workspace to reduce fatigue. Accessibility advancements included standard wheelchair lifts with full flat-floor designs in select models, such as the SLF transit buses and special-needs school bus variants, ensuring compliance with Americans with Disabilities Act requirements while facilitating easier boarding for passengers with mobility challenges. These innovations underscored Thomas Built Buses' shift toward more versatile, user-centered products under Daimler ownership.

Modernization and sustainability focus (2010s–present)

In the 2010s, Thomas Built Buses emphasized through the introduction of options and sustainable practices. The company launched propane-fueled versions of its Minotour Type A in 2012, powered by a Roush CleanTech system that reduced emissions compared to traditional diesel models. By 2013, it began production of a (CNG) variant of the Minotour, featuring Type 1 CNG tanks with a 26 gasoline-gallon equivalent capacity and certification to exceed EPA and standards. Additionally, in 2011, the High Point facility achieved zero-waste-to-landfill status by diverting over 90% of waste through and programs, complemented by installations to support greener operations. This era culminated in 2017 with the debut of the Saf-T-Liner C2 Jouley, the company's first all-electric prototype, designed for urban routes with a focus on zero-emission performance. Entering the 2020s, Thomas Built Buses encountered significant operational hurdles from the , including temporary production halts and broader disruptions affecting the automotive sector. In March 2020, the company suspended operations at its High Point plant for two weeks following an employee diagnosis, prioritizing health protocols amid widespread industry shutdowns. The second quarter of 2020 proved particularly challenging, with Daimler Trucks —Thomas Built's parent—reporting reduced output due to pandemic-related constraints on manufacturing and logistics. In response, the company integrated digital tools to enhance resilience, such as advanced inventory management and remote monitoring systems, aligning with industry-wide shifts toward Industry 4.0 technologies to mitigate future disruptions. These adaptations helped stabilize operations as s gradually recovered post-2022. From 2024 onward, Thomas Built Buses ramped up investments in its Type D bus lines to modernize production and boost efficiency. In July 2024, the company announced continued commitment to Type D vehicles with the introduction of the Saf-T-Liner HDX2, featuring enhanced Saf-T-Net construction, automated painting processes, and streamlined wiring for easier maintenance. By early 2025, production of Type D models fully transitioned to the newer facility, retiring the legacy line and enabling faster assembly times for the HDX2 and the newly launched Saf-T-Liner EFX2, which incorporates a 6.7L ISB engine delivering 200-260 horsepower. This shift supported increased capacity and incorporated electric-ready platforms, such as the HDX2 base for future zero-emission variants. In October 2025, the company introduced the Wattson, its first all-electric Type D , available for order by the end of 2025 with deliveries starting in late 2026. In September 2025, consolidated Thomas Built Buses with Freightliner Custom Chassis Corporation into a unified Specialty Vehicles division, aiming to streamline operations and foster innovation across 3,000 employees. Under the of T.J. Reed, appointed president and CEO of both entities in September 2024, the reorganization emphasized focused growth in sustainable mobility while maintaining Thomas Built's headquarters. Reed, a Daimler veteran since 1998, has guided the company through these changes, highlighting customer-driven strategies for fuel and powertrain options.

Products

Conventional school buses

Thomas Built Buses offers a range of conventional school buses designed for non-electric propulsion, categorized into Type A, Type C, and Type D models to suit varying route needs and passenger volumes. These buses emphasize safety, durability, and compliance with (FMVSS), while integrating customizable seating configurations and components from parent company for enhanced reliability. The Type A is a compact, front-engine built on van-cutaway , ideal for small districts or short routes with limited loads. It accommodates up to 30 and features wheelbases of 138–159 inches on Ford or , with a gross rating (GVWR) ranging from 9,900 to 14,500 pounds. Powered by engines such as the 6.0L V8 on GM or 6.8L V10 on Ford, the Minotour includes elements like a reinforced cage with one-piece roof bows, internal crash rails, and four-wheel anti-lock brakes, ensuring full FMVSS and Canadian Safety Standards (CMVSS) compliance. For mid-size routes, the Type C Saf-T-Liner C2 employs a forward-control configuration with the engine ahead of the , providing versatile capacity for 60 to 84 passengers in standard setups. Available in wheelbases from 158 to 279 inches and a GVWR up to 33,000 pounds, it supports diesel engines like the DD5 (200–240 hp) or B6.7 (200–260 hp), alongside and (CNG) options for compatibility. Key design features include a panoramic for 25% improved visibility over traditional Type C buses, Saf-T-Net tubular framing for structural integrity, and double-bolted body mounts, all meeting or exceeding FMVSS/CMVSS requirements. The Type D Saf-T-Liner HDX2, a rear-engine model rolled out in 2024 and fully available as of 2025, targets high-capacity urban and long-haul routes with up to 90 passengers. Its flat-nose transit-style design offers 78 inches of interior headroom, a large curved two-piece for optimal forward visibility, and an "S"-shaped drop-frame that positions the fuel tank between the rails for balance. Equipped with diesel engines such as the B6.7 (240–300 hp) or L9 (260–300 hp), the HDX2 incorporates advanced safety via Saf-T-Net construction, a double rear bumper, and integration of Daimler electrical architecture for future-proofing systems like optional 360-degree cameras and , while adhering to FMVSS/CMVSS standards. Across these models, shared attributes include ergonomic driver compartments with adjustable pedals and air-ride seats, corrosion-resistant exteriors, and modular designs allowing for lifts or high-back seating to meet district-specific needs, all supported by Daimler Truck's expertise for seamless parts commonality and maintenance.

Electric school buses

Thomas Built Buses entered the electric market with the introduction of the Saf-T-Liner C2 Jouley in , marking the company's first battery-electric offering designed specifically for school transportation. The Jouley, a Type C model powered by Proterra's electric drivetrain, underwent initial pilot programs starting in 2019 with select school districts to test its performance on typical routes, focusing on zero-emission operation and integration with existing fleets. These early deployments demonstrated the bus's capability for up to 120 miles of range on a single charge, supported by DC fast charging that completes a full recharge in approximately three hours. In January 2025, Thomas Built Buses unveiled the second-generation Jouley, incorporating an integrated 14Xe eAxle from Accelera by and an 800-volt Proterra battery system to enhance , , and overall distribution. This update optimizes power delivery directly to the wheels, reducing energy loss and improving vehicle efficiency compared to the original model, while maintaining a 246 kWh battery capacity suitable for daily school routes. The Gen 2 Jouley also introduces a 219-inch option for up to 60 passengers, emphasizing maneuverability in urban and suburban environments. Expanding its electric portfolio to Type D configurations, Thomas Built Buses launched the Saf-T-Liner eHDX2 Wattson on October 21, 2025, as the company's inaugural fully electric transit-style . Orders will open by the end of 2025, with initial deliveries scheduled for late 2026. Featuring a 246 kWh battery pack, the Wattson achieves an estimated range of up to 150 miles per charge, with standard SAE CCS1 DC fast charging at 120 kW enabling a full recharge in 2-3 hours or opportunity charging for extended operations. Optional AC 20 kW charging provides flexibility for lower-power infrastructure, and the model supports (V2G) capabilities to contribute to grid stability during peak demand. For Type C electric options like the updated C2 Jouley, Thomas Built Buses targets urban routes with shorter daily mileage, offering configurations that prioritize quick charging and for efficiency. These models include comprehensive battery warranties, such as up to 10 years covering capacity retention and thermal management, alongside infrastructure support through the company's Electric Bus Authority program, which assists districts with site assessments, planning, and grant navigation. As of March 2024, Thomas Built Buses had delivered its 1,000th electric across . Key deployments include partnerships with districts such as Meriwether County Schools in Georgia, which received eight Jouley units in 2024, and the Department of Education's order of 160 electric buses for statewide zero-emission pilots. Additional collaborations, like those with Valley View ISD in and districts, have integrated electric fleets for routes averaging 40 miles daily, reducing emissions and operational costs while gathering data for broader scalability.

Commercial and specialty buses

Thomas Built Buses has expanded beyond school transportation into commercial and specialty vehicles since the 1990s, offering adaptable platforms for transit, shuttle, and customized applications. These products leverage the company's expertise in durable construction and safety features, often derived from school bus chassis but modified for non-educational uses such as municipal routes, airport transfers, and group transport for organizations. In the early , Thomas Built introduced the TL960, a medium-duty rear-engine built on a , designed for urban and suburban routes with a capacity of up to 40 passengers and featuring a at the center door for . This model served operators like Greensboro Transit Authority, the University of Maryland, , and the Los Angeles County Metropolitan Transportation Authority, marking an early foray into commercial transit before production ended in the early . The company's current commercial lineup centers on the Transit-Liner C2, a versatile Type D bus customizable for shuttle and transit services, accommodating up to 52 passengers with a gross vehicle weight rating (GVWR) of up to 33,000 pounds and options ranging from 158 to 279 inches. Key features include all-steel construction, a low-profile hood for better visibility, 78-inch headroom, and options for coach-style seating, overhead luggage racks, video systems, tinted windows, , LED destination signage, and Wi-Fi integration. Power comes from the DD5 engine (200-240 horsepower, 560-660 lb-ft torque) or Cummins B6.7 (200-260 horsepower, 520-660 lb-ft torque), with wheelchair lift options ensuring ADA compliance for accessible transport. systems like Zonar V4 and Connect support , and the bus carries a three-year/50,000-mile warranty. For specialty applications, Thomas Built offers the MyBus, a compact multi-function on a cutaway , seating up to 30 passengers and tailored for churches, service organizations, and small group shuttles like or event transfers. Built with a steel-cage body using 14-gauge bow frames and 16-gauge aluminum side panels, it exceeds (FMVSS) for occupant protection with padded seats, emergency exits, and safety mirrors, while providing 73-inch headroom and driver-focused ergonomics. Customizations include rearview cameras, heated mirrors, organizational logos, storage compartments, and , with a three-year/36,000-mile warranty and five-year/100,000-mile coverage; ADA-compliant access is available via optional lifts. Post-1990s growth in commercial offerings involved partnerships within the family, integrating engines for enhanced reliability in tour and shuttle buses, while emphasizing durable, low-maintenance bodies for private operators. As of 2025, these non-school products represent a niche segment, focusing on customization for sectors like and community services rather than high-volume production.

Operations

Manufacturing facilities

Thomas Built Buses' primary manufacturing operations are centered at its facility in , the original site established in for producing early bus bodies. Over the decades, the plant has expanded significantly, including the addition of a 275,000-square-foot state-of-the-art facility in 2004 dedicated to assembling the Saf-T-Liner C2 Type C , incorporating advanced body construction and assembly lines. In March 2025, the company completed a key production transition by fully shifting Type D bus to the renamed Saf-T-Liner facility in adjacent Archdale, , a modern module designed for enhanced efficiency, , and integration. This move supports streamlined assembly of updated models such as the Saf-T-Liner EFX2 and HDX2, while Type C and Type A buses, including specialized Minotour vehicles, remain at the original High Point site. Complementing these operations, Thomas Built Buses integrated with Freightliner Custom Chassis Corporation (FCCC) in , following a September 2025 consolidation into Daimler Truck Specialty Vehicles. The facility handles chassis assembly and customization, supplying purpose-built components directly to High Point and Archdale for final bus integration, optimizing overall production logistics. The High Point and Archdale plants incorporate automated welding and painting systems, enabling flexible high-volume output to address growing demand for school and commercial buses, with recent shifts and expansions supporting daily production rates of around 40 units across multiple shifts.

Production innovations

In the 2010s, Thomas Built Buses integrated robotic welding systems into its assembly processes at the facility, enhancing precision and consistency in body framing alongside skilled manual labor. These advancements, supported by inspection of over 200 critical points per bus, contributed to overall production efficiency, including a 30% reduction in downtime through via IoT sensors. Safety innovations have been a cornerstone of production updates, with (ESC) becoming a standard factory-installed feature on all new Saf-T-Liner C2 diesel and models starting in 2018, helping maintain vehicle control during adverse conditions. By 2020, the integration of the PV360 camera system provided drivers with a 360-degree bird's-eye view around the bus, improving pedestrian and obstacle detection during loading and maneuvering. Sustainability efforts in production reached key milestones by 2025, aligning with North America's goals to reduce volatile organic compounds (from paints and coatings), , waste generation, and water usage across all manufacturing plants. This included the adoption of low-VOC, energy-efficient paint systems and the expansion of zero-waste-to-landfill practices, initiated in 2010, which incorporate recyclable materials throughout assembly to minimize environmental impact. installations at facilities further supported these energy-efficient operations. Customization processes leverage principles, particularly in chassis-body integration with Freightliner Custom Chassis Corporation, allowing flexible matching of components to customer specifications. technology and simulation tools streamline this by reducing new model development time from 36 to 24 months, enabling just-in-time manufacturing with over 300 domestic suppliers for tailored options like lighting, interiors, and USB ports.

References

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