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Capacity Expansion

Pierce is investing to deliver quality fire trucks to your firehouse faster.

Driving Capacity Growth.

See how Pierce is delivering quality fire trucks to your firehouse faster.

Overview

Since 2022, Pierce Manufacturing has embarked on a multi-year transformation designed to strengthen its production capacity, enhance quality and reduce lead times for fire apparatus nationwide.

Through major facility expansions, cutting-edge technology and strategic workforce growth, Pierce is investing in the future of apparatus manufacturing in the United States. 

These initiatives reflect a deep commitment to innovation, efficiency and reliability, ensuring every apparatus is built faster, smarter and with the same uncompromising standard of excellence.

Fire Trucks on the Blue Floor

~
500,000

 sq. ft. added to our facilities.

+800

new American jobs created in the last 3 years and we're still hiring.

$
71.9
Million

invested in manufacturing facilities. This is part of a $150+ million commitment across facilities in Wisconsin, Florida and Tennessee.

Following a historic 50% surge in demand from 2019-2022, Pierce has invested in facility expansions, technology and workforce growth to boost capacity and production efficiency.

 

Facility Advancements

From welding, sanding and paint robots to AI-enabled sanding systems, laser technology and collaborative robots (cobots), Pierce has invested in new automation and precision technologies which are reshaping fabrication and assembly processes. Each investment is designed to enhance quality, increase production flow, reduce manual touchpoints and improve safety for team members.

Appleton, Wisconsin

 Cutlite-Penta Fiber Plus Bevel 30K Laser 

One of only two in the U.S., this high-powered laser is capable of cutting up to two inches of steel with beveled edges, eliminating manual sanding. This investment boosts precision and efficiency while reducing rework, helping our team build fire apparatus faster and with unmatched accuracy.

Panel Bender

This automated panel bender performs multiple bends in a fraction of the time required by traditional presses, helping our teams create components that fit perfectly, every time.

Folding Machine

This semi-automated folding machine allows a single operator to perform complex bends safely and efficiently. 

Automated Rail Welding

This cutting-edge automated rail welding systems reduces welding time by up to two-thirds, while delivering consistent, strong and reliable welds every time.

Handheld Laser Welding

Handheld laser welding technology delivers precise results with minimal material warpage. 

Buffing Robots & AI-Enabled Sanding System

Buffing robots and an AI-enabled sanding system prepares metal panels for paint with improved consistency and efficiency.

Paint Facility Expansion

The new 26,000 square foot paint facility expansion in Appleton, Wisconsin features new advanced wet dust collection sanding booths. They are equipped with ergonomic personnel lifts and augmented with automated sanding and buffing. This boosts capacity and ensures each fire truck receives a flawless finish.

Manufacturing Release Line Relocation

The Manufacturing Release Line (MRL) has relocated within our Appleton, Wisconsin facility. This move improves production flow, increases voice of internal customer feedback and enhances quality control on every apparatus.

Parts Expansion

A modernized 224,000 square foot facility, including parts storage frees critical manufacturing capacity and further enhances efficiency and quality.

Ergonomic Turntable Positioner

The ergonomic turntable positioner increases efficiency when manufacturing aerial turntables. The device rotates the aerial turntable providing team members with easier access from every angle while enhancing a safe work environment.

Chassis Line Relocation

The chassis line has relocated and been reformatted. In the new format, work content is evenly distributed amongst the team to improve overall efficiency and quality. This new line structure improves material delivery and flow to increase the utilization of our space and reduce downtime. 

Bradenton, Florida

Sheet Metal Folder

The new folding machine enhances fabrication capabilities. This machine improves efficiency, consistency and workflow across Pierce's operations. This investment also supports enhanced ergonomics and team member safety.

Amada Turret Punch

The new laser cutting system streamlines material flow and reduces manual handling. This shortens production time, elevates quality and helps increase safety.

Saber Chassis Line Expansion

The Saber chassis line has been expanded which creates space for additional workstations. This enhances workflow efficiency, safety, quality and production capacity.

Paint Booth Capacity

Expanded paint operations include the addition of a new booth space and material-handling enhancements. This supports increased capacity, improved production consistency and exceptional quality.

Robotic Welding System

The new robotic welding system enhances an already proven welding process, delivering repeatable precision while increasing production capacity by strengthening quality and improving efficiency.

Additional 185,000 Square Foot Facility

A new 185,000 square foot facility will be in full operation by mid-2026 which enables expanded material storage and kitting, improved production flow and enhanced training capabilities.

Looking Ahead

A firefighter in turnout gear pulling hose from the crosslays on an Ascendant Aerial Ladder with a PUC pump on a sunny day.

 

Process modernization and strategic investments are driven to move Pierce closer to its goal: delivering quality fire trucks to your firehouse faster. 

  • Advanced technology
  • Manufacturing equipment investment
  • AI-driven quality systems
  • Facility expansions
  • Focus on team member safety and ergonomics

Together, these investments reflect Pierce’s commitment to continuous improvement, ensuring every truck meets the highest standards of performance, precision and reliability.

© 2026 Pierce Manufacturing, Inc.

Registered Trademark of Pierce Manufacturing Inc. Appleton, WI, USA an Oshkosh Corporation Business