Commercial Vehicles

Lightning expansion of commercial vehicle conversions


Commercial electric vehicle supplier Lightning Systems continues to grow and expand its operations. With more than $32 million in pending orders from commercial and government fleets, the company is more than tripling the size of its manufacturing, research and development facility in Loveland, Colorado.

Lightning Systems began converting their facility for expansion in January this year. The expansion has involved investment in new high-capacity vehicle and battery charging and testing systems, new fabrication and wiring harness equipment, semi-automated centres for conversion and powertrain testing and automation equipment. The expanded space is being used for and an increase in electric powertrain manufacturing and assembly for the Ford Transit, E-450, F-550, Class 6 truck and Class 8 motor coach.

“Our mission is to provide commercial fleets with the world-class battery-electric and fuel-cell electric vehicle solutions they need to meet the new Zero Emissions Zone regulations that are being quickly implemented throughout the world,” said Tim Reeser, CEO, Lightning Systems. “In addition to the Zero Emission Zone regulations, many fleets have adopted aggressive sustainability goals. These two market drivers are creating demand that will soon exceed the sum of EV makers’ abilities to produce vehicles, components, and charging solutions. Unlike most of the industry, we’re shipping vehicles now and rapidly expanding.”

With the recently completed expansion, Lightning Systems are now able to occupy the previous space entirely for conversions of commercial vehicles with electric powertrains. At the Loveland facility, Lightning systems will also be producing its recently presented Lightning Mobile DC charger (DCFC) for electric vehicles. The new chargers enable the rapid and flexible rollout of commercial vehicle charging infrastructure to support the operation of electric commercial vehicle fleets. Lightning recently received a Charge Ahead Colorado Grant to install new Level2 and DC Fast Chargers.

“The market is demanding end-to-end solutions and products that are not only green and sustainable, but fundamentally better, and we are excited to be delivering zero-emissions vocational vehicles and the energy and charging solutions to power them to meet that demand,” Reeser said.

Lightning Systems moved into its headquarters, manufacturing and R&D facilities in the former Hewlett-Packard/Agilent campus in Loveland three years ago. Taking over more buildings in the campus, the commercial vehicle conversion company recently expanded its square footage from 45,000 to 142,000 (in square metres: from 13,715 to 43,281).

This year, as hydrogen fuel cell technology is widely being recognised as an appropriate emission-free propulsion system for larger and long haul vehicles, Lightning Systems has positioned itself well. Just this February Lightning entered new cooperation with the New York-based fuel cell specialist Plug Power to offer Class 6 (up to 12.5 tons) trucks powered by fuel cells.


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