In 2005, McConnell Seats made a pivotal shift from traditional scissors and hand-cut templates to computerised precision, beginning a strategic partnership with Melbourne-based Pathfinder Cutting Technology. Two decades later, that collaboration continues to shape Australia’s bus and coach manufacturing industry through shared innovation, sustainability, and a commitment to local capability.
From Scissors to Smart Systems
The relationship began when Pathfinder founder John Hollo walked into McConnell’s facility and introduced himself to then-leaders Dennis McConnell and Alan Smith. At the time, the upholstery cutting process at McConnell was still manual, relying heavily on scissors and templates.
“Dennis and Alan quickly saw the future in digital technology,” said Wayne Walker, sales manager at Pathfinder. “Within months, we installed a CAD system and a K-Series CNC cutting machine at McConnell’s site.”
That forward-thinking investment helped transform McConnell into one of Australia’s leading manufacturers of bus and coach seating. Today, thousands of vehicles across the country feature seating produced using Pathfinder’s systems.
Next-Gen Technology for a New Era
Now, the long-standing partnership has entered a new phase with the installation of Pathfinder’s latest M-Series system, paired with the advanced FabricPro automatic material spreader.
“It’s faster, smarter, and more sustainable,” said James Lowe, General Manager of McConnell Australia. “The system helps us maximise material efficiency, reduce waste, and reduce our reliance on skilled manual labour, which is increasingly hard to source.”
Built for ease of use, minimal maintenance, and operational safety, the M-Series delivers cutting-edge speed and precision. It also allows McConnell to digitise its workflow, improving scheduling, data analysis, and workforce training.
A Local Partnership with National Impact
The partnership between McConnell and Pathfinder stands as a testament to the strength of local collaboration in Victoria’s manufacturing ecosystem. Pathfinder designs and manufactures all its machines and software within the state, working with over 200 local suppliers. This proximity ensures rapid service, support, and product innovation for clients like McConnell—something rarely possible with overseas suppliers.
“Strong local partnerships are the backbone of a resilient manufacturing economy,” said Lowe. “When you invest locally, you’re building stronger communities and future-proofing your supply chain.”
With approximately 80% of McConnell’s supply chain based in Victoria, Lowe emphasized the importance of preserving these relationships in a globally uncertain environment.
Supply Chain Ripple Effect
Major clients like Volgren, one of Australia’s largest bus body manufacturers, form critical links in this ecosystem. Lowe warned that any disruption in orders from Volgren and similar OEMs has a cascading effect on dozens of Victorian businesses, including McConnell.
“If Volgren’s orders decline, it doesn’t just affect us—it affects the entire supply chain,” he said. “Maintaining a strong, local bus and coach industry is essential for economic stability in the region.”
Manufacturing for the Future
After years of offshoring and underinvestment in Australian manufacturing, Walker believes the industry is now reawakening to the importance of sovereign capability.
“Our machines are built in Melbourne and used globally,” he said. “Australia still produces world-class products—you just need to know where to look.”
Walker emphasized that local partnerships have broader economic and social benefits. “Keeping supply chains and money local builds stronger industries and stronger communities,” he added.
Raising Safety Standards
McConnell is also leading the way in adapting to new Australian safety regulations. The company is updating its seating designs to comply with revised seat belt Australian Design Rules (ADRs). New features include visual and audible seatbelt reminders and clear labeling on seat backs encouraging passengers to “Fasten seat belts while seated.”
“Working closely with operators allows us to merge practical fleet insights with manufacturing expertise,” said Lowe. “We’re delivering solutions that are safer, more durable, and aligned with the industry’s evolving needs.”
A Model for Resilience and Progress
As expectations grow around safety, sustainability, and supply chain transparency, McConnell and Pathfinder remain at the forefront of innovation in Australia’s transport manufacturing sector.
Their enduring partnership highlights what’s possible when local companies invest in each other—not just in machinery and products, but in long-term vision and community growth.
“In today’s world, you innovate or get left behind,” said Walker. “Nobody’s going back to horse-and-cart manufacturing. And thanks to partnerships like this one, we don’t have to.”
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