About The Customer
Thomas Built Buses is one of the most iconic names in American school transportation, with over 100 years of experience designing and building buses for school districts across the country. A subsidiary of Daimler Truck North America, the company is recognized for its innovation, safety standards, and commitment to community impact.
The Challenge
At an industry show, an idea took shape. Thomas Built Buses wondered what it would look like to turn their flagship school bus into a LEGO collectible kit. The goal was irresistible—but the hurdles were real.
They needed the model to match the bus in shape and spirit. That meant working with exact physical dimensions and translating them into a LEGO‑compatible design. On top of that, the packaging had to feel premium enough for a keepsake, not just a giveaway.
The Solution
Avail took the idea from sketch to shelf with a process that prioritized collaboration, precision, and presentation.
Engineering to LEGO‑ready design
We worked hand in hand with Thomas Built’s engineers to pull accurate specs from the bus. From there, our designers crafted a 3D rendering that captured the right scale, angle by angle.
High‑quality production
Once the digital model was approved, we partnered with a trusted manufacturer to source parts that delivered on build quality, consistency, and ease of assembly.
Packaging as the final piece of the puzzle
Each kit arrived in retail‑style packaging designed to celebrate the build inside. Branded, clean, collectible-ready packaging made opening it feel like an experience.
The Outcome
The result was a model that gave just the right nod to the original—both in appearance and emotion. Every kit showcased:
- An exacting build powered by real design specs
- A curated, collectible feel from the moment of unboxing
- Fully branded packaging built to stand out and stay memorable
By the numbers:
- 500 LEGO bus kits created and delivered
- Design rooted in real engineering specs
- Packaging crafted to elevate the gift into a keepsake
With Avail’s design and execution, Thomas Built didn’t just produce swag—they created a moment, an experience, and a collector’s item.
TLDR
Thomas Built Buses wanted a LEGO version of their iconic school bus. Avail partnered with their engineers to design an accurate 3D model, sourced every piece for quality assembly, and wrapped it in sleek collectible packaging. The result: 500 memorable kits that feel custom‑made and brand right.
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