Turning a School Bus into a Collectible for Thomas Built Buses

Client Overview

Thomas Built Buses, a division of Daimler Truck, is a leading manufacturer of school buses in North America. Known for their attention to detail and commitment to safety, their vehicles are instantly recognizable across the country. As an Avail partner, they rely on our team to deliver standout merchandise and program execution that reinforces their brand and builds pride within their community.

The Challenge

While attending an industry trade show, both teams noticed a creative trend: companies using LEGO bricks to reimagine their products as miniature keepsakes. It sparked an idea...what if Thomas Built could bring their iconic yellow bus to life in LEGO form?

The idea was exciting, but it came with challenges. The bus needed to be an accurate model of their most recognized vehicle. That meant sourcing real-world specs, translating them into LEGO-compatible dimensions, and ensuring the final product looked and felt right. And because this wasn’t just a gift, it was a collectible. This meant it also needed to ship in packaging that was equally custom and high quality.

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The Solution

The Avail team led the project from concept to delivery. We started by collaborating directly with Thomas Built’s engineering team to review the actual bus’s specs and dimensions. From there, we translated the technical design into a 3D rendering that could be accurately recreated using LEGO-compatible components.

Once the design was finalized, we worked with a trusted manufacturer to bring the model to life to help with build quality, part availability, and ease of assembly. Alongside the product, we developed custom retail-style packaging to house each kit, giving the final product a polished, collectible feel.

The result was a one-of-a-kind piece that perfectly captured the essence of Thomas Built’s most iconic vehicle.

The Outcome

• 500 custom LEGO bus kits produced and delivered
• Design based on actual engineering specs from Thomas Built’s manufacturing team
• Unique, brand-forward retail packaging developed in collaboration with the client
• The project turned a fun idea into a memorable and fully branded promotional item that employees, partners, and clients all loved

With Avail’s creative and logistical support, Thomas Built didn’t just give away swag—they created a lasting impression.

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