Custom Denning Announces the 100th Element 2 Bus Milestone: A Vision for the Future of Public Transport

March 12, 2025

Custom Denning Announces the 100th Element 2 Bus Milestone: A Vision for the Future of Public Transport

Custom Denning, Australia’s oldest bus manufacturer, is proud to announce the completion of its 100th Element 2 electric bus. This landmark achievement is a testament to the company’s dedication to innovation, sustainability, and excellence in local manufacturing. With this milestone, Custom Denning solidifies its position as a leader in zero-emission transportation and looks forward to an exciting future of greener, smarter public transit solutions.

A Journey of Innovation: The Evolution of the Element Series

The Element series has come a long way since its inception.The first Element bus was completed in 2020, marking the beginning of a new era for Custom Denning. By 2021, the Element was added to the Transport for NSW (TfNSW) procurement panel, making it eligible for government contract purchases and further cementing its place in Australia’s transition to a zero-emission transport future. The first production Element bus was delivered in November 2021, and by December 2022, an impressive 50 Element buses had been manufactured and delivered.

The year 2023 marked a pivotal moment for Custom Denning with the release of the Element 2, an upgraded version of the original model. This new iteration was designed to meet evolving industry needs and fulfill a significant government order for 49 buses. The Element 2 also made its international debut that year, with the first unit exported to the UK, followed by another nine buses delivered overseas in 2024. As of March 10,2025, Custom Denning has manufactured 103 Element 2 buses, with 93 already delivered to customers. Combined with the original Element series, this brings the total number of buses produced by Custom Denning to an impressive 184 units.

What Makes the Element 2 Stand Out?

The introduction of the Element 2 marked a significant leap forward in electric bus technology and design. While retaining many of the core strengths of its predecessor, the Element 2 incorporates several key upgrades that make it more efficient, reliable, and versatile. Here are some of the standout differences between the original Element and the new Element 2:

  1. Enhanced Performance: The Actia drive motor used in the original model has been upgraded with a ZF CeTrax drive motor. This new motor offers higher torque and improved efficiency, ensuring smoother performance and greater reliability.
  2. Advanced Battery Technology: The switch from Lithium Metal Polymer (LMP) solid-state batteries to Nickel Manganese Cobalt (NMC) lithium-ion     batteries represents a significant improvement in energy density and durability.
  3. Upgraded High-Voltage System: The high-voltage system has been completely upgraded, giving Custom Denning full control over all software and system updates. This allows for faster modifications and troubleshooting without relying on overseas support—a key advantage for operators.
  4. Modernised Design:The Element 2 features an external facelift with redesigned headlights and front corner panels that give it a sleek, modern appearance
  5. Optimised Dimensions: The bus length has been reduced from 12.5 meters to 12 meters, improving manoeuvrability on tight city streets and reducing rear corner damage—a common issue in urban environments. Additionally, operators now have the option for a shorter 10.5-meter version, offering even greater flexibility for route planning.
  6. Pantograph Charging Capability: Unlike the original model, the Element 2 supports fast charging via a pantograph system. This allows for rapid recharging at up to 450kW, enabling a full charge in just one hour—ideal for high-demand urban routes.

Cutting-Edge Features Driving Public Transport Forward

The success of Element 2 can be attributed to its innovative design and advanced features tailored to modern public transport needs:

  • Flexible Length Options: Operators can choose between 10.5-meter or 12-meter versions to suit different route requirements.
  • Durable Construction: A stainless steel chassis and frame ensure long-lasting durability.
  • High-Capacity Batteries: Two battery capacity options—383kWh or 462kWh—provide flexibility based on operational needs.
  • Fast Charging Options: The buses support both plug-in CCS Type 2 charging (3¼ hours) and overhead pantograph charging (1 hour), ensuring minimal     downtime.
  • Powerful Drive System: The ZF CeTrax drive motor delivers up to 300kW of power and an impressive torque rating of 4,500Nm, ensuring smooth acceleration even on challenging routes.
  • Efficient Charging Rates: With maximum charging capabilities of up to 150kW via plug-in or up to 450kW via pantograph charging, operators can recharge quickly during layovers or at depots.

A Global Vision with Local Roots

While Custom Denning remains proudly Australian-owned and operated, its global ambitions are clear. The export of ten Element 2 buses to the UK demonstrates that Australian-made electric buses can compete on an international stage. These exports not only showcase Custom Denning’s engineering excellence but also contribute to Australia’s reputation as a leader in sustainable manufacturing.

Looking Ahead: A Greener Future Awaits

The purchase of the 100th Element 2 bus is more than just a milestone—it’s a symbol of progress toward a cleaner, more sustainable future for public transportation. As cities around Australia—and indeed around the world—continue their transition toward zero-emission fleets, Custom Denning is poised to play a central role in this transformation.

With its innovative technology, commitment to quality, and vision for sustainability, Custom Denning is not just building buses; it’s building a better future for communities everywhere. As we celebrate this achievement, we look forward with excitement to what lies ahead—for Custom Denning, its partners, and passengers worldwide who will benefit from these cutting-edge vehicles.

Here’s to many more milestones as we continue driving innovation forward!

Stay tuned for more information coming soon.