It’s rare that building projects are completed on time without delay, let alone early, but that’s exactly what happened in Plattsburgh, New York. 

In late 2024, Quebec-basedMicro Bird announced plans to expand its manufacturing operations with a new U.S. facility. Just seven months and $38 millionlater, the former Nova Bus facility had been expanded and converted to accommodate doubled production capacity for the company’s Type A buses.

We checked in with Eric Boulé, Micro Bird CEO and president, to learn more.

Q: Tell us more about your new U.S. facility! How long has it been in the works and how did you pick the location?

Boulé: Since 1966, Micro Bird has been manufacturing high-quality small and medium-sized buses for both the school and commercial markets across North America. Through continued investment in innovation and research & development, we strive to deliver the best-in-class products using EV, gas, and propane powertrain technologies.

Expanding Micro Bird’s operations in the U.S. has long been part of our vision. As our market presence in the U.S. continued to grow, that vision became a strategic necessity. Customers, dealers, and public agencies were increasingly looking for high-quality, U.S.-built Micro Bird products, particularly for publicly funded projects. 

Establishing a manufacturing presence in the U.S. was a natural way to align with those expectations, and Plattsburgh stood out early in the process. It offers a strong manufacturing ecosystem, access to a skilled workforce, and close proximity to our existing operations in Québec, which supports close collaboration and knowledge sharing. From the outset, the facility was designed with flexibility, scalability, and long-term competitiveness in mind.

We’re also fortunate to build on the strength of our joint venture between Blue Bird Corporation and Girardin Holdings. That alignment gives us deep insight into the U.S. market and helps ensure our go-to-market approach, dealer engagement, and operational priorities remain closely aligned with customer expectations across the country. 

Opening ahead of schedule was a meaningful achievement for our teams. Launching a new facility brings its share of adjustments, but the early results reflect our strong foundation and focused, disciplined approach.

One year after the acquisition and seven months into operations, the team in Plattsburgh has demonstrated a high level of expertise, along with a strong culture focused on quality, health and safety, and the agility required of a high-performing manufacturing operation. That progress has been supported by close collaboration between our Canadian and U.S. teams, which has been essential in establishing solid operations in New York.

We’ve also benefited from strong support within the local business community, including the Town of Plattsburgh, Clinton County, the North Country Chamber of Commerce, and the state of New York. That collaboration has played an important role in helping the facility ramp up successfully and to integrate into the regional manufacturing ecosystem.

Q: Your new facility is fully compliant with the Buy America Act. Have your supply chain and component-sourcing strategies changed as a result?

Boulé: Achieving Buy America Act compliance was a significant objective for this facility and required a comprehensive review of our supply chain. We worked closely with our existing partners while expanding our network of U.S.-based suppliers to ensure that key components meet domestic content requirements.

Beyond compliance, this has strengthened our supply chain overall. It allows us to better support federally funded programs and gives customers greater confidence when selecting Micro Bird. Most importantly, it reflects our long-term commitment to the U.S. and Canadian markets and to meeting the expectations of public agencies and transportation providers.

Q: You’ve emphasized growth in the small and mid-sized school and commercial bus segments. What specific product lines or industry niches will you serve from the U.S. facility that you couldn’t before?

Boulé: The Plattsburgh facility significantly expands our manufacturing capacity, allowing us to meet growing demand for Micro Bird vehicles that are widely recognized for their reliability, quality, and low total cost of ownership. This expansion supports both the school and the commercial markets, with a strong focus on small and medium-size commercial and transit applications.

By effectively doubling our production capacity, the Plattsburgh facility also enables us to better serve customers who require U.S.-built vehicles for publicly funded projects. Building on capabilities we already have, this added manufacturing presence enhances our ability to deliver purpose-built configurations that respond to customer needs, while maintaining the performance, durability, and value customers expect from Micro Bird.

Q: What are your projected milestones for the next year, and how will you measure success and consider customer feedback?

Boulé: Over the next year, our focus will be on continuing to build momentum at the Plattsburgh facility while advancing the implementation of our operational excellence program and best manufacturing practices. Key milestones include further increasing production capacity, strengthening workforce stability, and striving to meet Micro Bird’s high standards for efficiency, productivity, and quality.

Success will be measured through operational performance and customer satisfaction, working closely with our dealer network across North America. Our dealers play a critical role by providing proximity to customers and strong service capabilities, and that partnership is essential as we continue to grow together.

We’ve already welcomed several customers to the facility, and we look forward to hosting many more, alongside our dealers, so they can see firsthand the plant, the team, and the culture of excellence and customer-focused production we’ve put in place.

Q: What are your long-term vision and goals for Micro Bird’s North American presence, and how does the New York facility position you for future growth and success?

Boulé: Our vision is to continue strengthening Micro Bird’s presence across North America, building on our leadership in the small and medium bus segment and expanding into select school and commercial applications. Micro Bird has always been about taking a long-term view and building safe, reliable vehicles, and the decision to invest in U.S. manufacturing fits squarely within that philosophy.

As we approach our 60th anniversary in 2026, our focus remains rooted in what has defined Micro Bird since the beginning: building safe, reliable vehicles for student transportation. That legacy continues to guide our decisions today, including investments in manufacturing, quality, and processes that support the highest standards of safety.

This facility positions us well for the next chapter of growth, while staying true to the principles that have earned the trust of school districts and transportation providers over decades.