Blue Bird Unveils Latest Zero- and Ultra-Low Emission Commercial Vehicles at 2025 ACT Expo
Blue Bird Corporation (Nasdaq: BLBD), a leading manufacturer of electric and low-emission school buses, is taking center stage at the 2025 Advanced Clean Transportation (ACT) Expo—North America’s premier event for sustainable transportation technology—by showcasing its newest innovations in clean commercial vehicle platforms. At Booth 5488 in the Anaheim Convention Center, Blue Bird is presenting both its state-of-the-art electric-powered step van and an all-new propane-powered stripped chassis, underscoring the company’s bold move into the commercial vehicle space.
With a legacy rooted in school bus manufacturing and a growing footprint in zero- and low-emission technology, Blue Bird is leveraging its experience and strategic industry partnerships to develop commercial transportation solutions that meet the evolving needs of fleet operators nationwide.
Blue Bird’s Electric-Powered Step Van: Redefining Last-Mile Delivery
At the heart of Blue Bird’s display is a cutting-edge electric-powered step van, designed on the company’s robust Class 5-6 stripped chassis platform. Tailored specifically for last-mile delivery applications, the step van boasts a 178-inch wheelbase and a gross vehicle weight rating (GVWR) of up to 23,000 pounds—providing an ideal combination of space, strength, and electric efficiency.
Powering the step van is a 140kWh lithium-ion battery system, engineered for durability and performance. To ensure maximum safety and structural integrity, the battery pack is strategically mounted within the frame rails of the chassis. This positioning helps protect the batteries from road debris, weather conditions, and impact, contributing to the vehicle’s overall longevity.
In terms of range, the electric step van can travel up to 130 miles on a single charge—well suited for daily urban and regional delivery routes. Charging times vary from one to twelve hours, depending on the capacity of the installed infrastructure. This makes the vehicle a flexible option for fleets with diverse operational demands and varying access to charging facilities.
Enhanced Driver Safety and Familiarity
Recognizing that fleet adoption depends heavily on the user experience, Blue Bird has integrated a suite of innovative features to aid driver safety and comfort—some of which are uncommon in comparable electric delivery vehicles. These features include:
- Hill Hold Assist: Prevents the vehicle from rolling backward or forward when stopped on an incline, reducing driver fatigue and enhancing control.
- Electric Creep Functionality: Mimics the behavior of traditional internal combustion engine vehicles by allowing the van to slowly move forward when the brake is released, offering a smoother transition for drivers accustomed to gas-powered drivetrains.
Additionally, the vehicle platform boasts a best-in-class 55-degree wheel cut, optimizing maneuverability in tight urban environments—a key advantage for operators navigating congested city routes.
Propane-Powered Stripped Chassis: A First-of-Its-Kind OEM Solution
Alongside its electric offering, Blue Bird is unveiling a new propane-powered stripped chassis built on a 208-inch wheelbase. Also designed for Class 5-6 applications, this vehicle accommodates medium- to long-range delivery operations with a GVWR of up to 23,000 pounds.
The propane chassis marks an industry milestone as the first OEM-installed propane powertrain solution in this class. It features Ford Motor Company’s trusted 7.3-liter V8 engine, known for its durability, reliability, and ease of maintenance. The powertrain, producing 335 horsepower, has been seamlessly integrated by Blue Bird in collaboration with long-time partners Ford and ROUSH CleanTech.
By utilizing lightweight components and innovative materials, Blue Bird enhances the fuel efficiency and payload capacity of its propane platform, while upholding its commitment to safety and performance.
ROUSH CleanTech Partnership: Proven Low-Emission Technology
Blue Bird’s propane-powered commercial chassis builds upon its enduring partnership with ROUSH CleanTech, a pioneer in alternative fuel technology. ROUSH provides the proven propane fuel system that powers the new vehicle, bringing to the table over three billion miles of cumulative experience with 3,000 fleet operators across North America.
“Our collaboration with Blue Bird since 2012 has centered on delivering dependable, lower-emission solutions for fleets,” said Todd Mouw, Executive Vice President of Sales, Marketing, and Customer Success at ROUSH CleanTech. “Propane is a domestically sourced, cost-effective fuel that delivers substantial emissions reductions and financial savings—all without sacrificing vehicle performance.”
Propane as a fuel offers key advantages, including lower carbon intensity compared to diesel, reduced maintenance requirements, and lower operating costs. These benefits make it a compelling option for fleet managers seeking to transition to cleaner technologies with minimal operational disruption.
Strategic Expansion into Commercial Transportation
With its latest vehicle platforms, Blue Bird is strategically extending its reach beyond school buses and into the commercial vehicle market, building on a century of engineering excellence and a well-earned reputation for safety and reliability.
“Blue Bird is proud to bring our decades of expertise in clean and safe transportation to a new segment,” said Andy Moore, Director of Commercial Chassis at Blue Bird Corporation. “Our electric and propane vehicle platforms offer a powerful value proposition for fleet operators looking to improve efficiency, reduce costs, and meet environmental goals. The ACT Expo is an ideal venue to connect with the industry and showcase how we are shaping the future of sustainable transportation.”
Both the electric and propane stripped chassis platforms are expected to be commercially available in the first quarter of 2026. As the demand for environmentally responsible and cost-effective fleet vehicles continues to rise, Blue Bird’s offerings stand out as timely solutions ready to meet the market’s needs.
A Clean Transportation Leader with Deep American Roots
Blue Bird is the only U.S.-owned and operated school bus manufacturer in the country, proudly designing and building its vehicles in Fort Valley, Georgia. The company has long been a leader in clean transportation, with more than 25,000 alternative fuel-powered school buses—powered by propane, natural gas, and electricity—sold across North America.
In addition to advancing transportation innovation, Blue Bird plays a significant role in supporting the U.S. economy, helping sustain approximately 2,000 well-paying jobs through its manufacturing and operations.
As fleet operators across commercial sectors seek cleaner, smarter, and more efficient ways to deliver goods and services, Blue Bird’s expansion into the commercial chassis market signals a pivotal step toward electrification and emissions reduction—while remaining firmly grounded in its legacy of safety, quality, and American manufacturing excellence.
