Lightship, the Broomfield, Colorado-based all-electric recreational vehicle manufacturer, is expanding its factory by approximately 44,000 square feet to meet growing demand for its AE.1 travel trailer. The expansion will bring the company’s total manufacturing footprint to roughly 76,000 square feet and more than quadruple its existing production capacity by the end of 2026.
Highlights
- Facility nearly doubles in size: Lightship’s 32,000-square-foot Broomfield plant grows to approximately 76,000 square feet, with construction already underway and operations expected this summer.
- Production capacity quadruples: The expanded facility will increase output more than fourfold by year-end 2026, adding manufacturing jobs in Colorado.
- Simplified AE.1 lineup: Lightship is shifting to a single configurable model starting at $157,500, with the 77 kWh battery now standard across all builds.
- Domestic sourcing emphasis: Eighty percent of the AE.1’s component value is sourced within the United States.
Expansion Details
Lightship’s current facility at 1765 W. 160th Ave. in Broomfield will grow by roughly 44,000 square feet. Construction is already underway, with operations in the new space expected to begin this summer. The full expansion is projected to take approximately 18 months to complete.
The company, which raised $26.6 million last year, said the additional space will increase vertical integration while also expanding service and R&D capabilities for future product development.
“This expansion is a defining moment for Lightship,” said Toby Kraus, CEO and co-founder of Lightship. “At a time when many companies in this category are outsourcing their production and supply chain overseas, we’re doubling down on our commitment to American manufacturing, accelerating innovation and creating high-skill jobs in a region emerging as a hub for next-generation mobility.”
Streamlined AE.1 Configuration
Alongside the facility expansion, Lightship is consolidating its AE.1 lineup into a single configurable model with an adjusted starting price of $157,500. The 77 kWh battery pack — roughly 60 times the size of a standard trailer battery and previously exclusive to the $184,000 Atmos trim — is now standard equipment on all AE.1 builds.
The company said over 90 percent of its customers had already selected the 77 kWh pack, making the decision straightforward. New configuration options will let buyers tailor the trailer for home backup power, extended travel, short-term rental use, and full-time living.
“More than ninety percent of our customers have chosen the 77 kWh battery. This new lineup makes this popular feature more accessible. We are also adding options to give customers the flexibility to tailor the product for home backup, extended travel, short-term rental use, and full-time living,” said Ben Parker, co-founder and chief product officer of Lightship. “Because we are a direct-to-consumer brand that builds and sources in the U.S., we can incorporate real-world feedback into product improvements on a much shorter cycle.”
U.S. Supply Chain and Board Addition
Lightship’s manufacturing approach centers on domestic sourcing and close supplier collaboration. The company says 80 percent of the AE.1’s component value is sourced within the United States, providing tighter quality control and reduced exposure to global supply chain disruptions.
The company also announced the appointment of Tom vonReichbauer to its board of directors. VonReichbauer brings more than two decades of experience scaling hardware and technology companies, with leadership roles at Tesla, Nest, Sunrun, Google, and ICON.
Founded in 2020 and co-headquartered in Broomfield and San Francisco, Lightship designs and manufactures its products domestically and sells directly to consumers. The electric RV segment has seen increased activity in recent months, with competitors including Pebble, Evotrex, and Grounded also scaling production of all-electric travel trailers and camper vans.
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