G-Class Tram | Next Generation Tram Design & Development

Melbourne is on the brink of a transformative shift in public transport with the rollout of its next-generation light rail vehicles, the G Class tram. With local manufacturing, modular repair designs, sustainability features, and enhanced passenger comfort, these trams signify more than just a fleet update, they represent a bold commitment to smarter, greener urban mobility.

Recently, a full-scale mock-up was unveiled in a confidential northern Melbourne facility, offering a comprehensive preview of what’s to come.

This article provides a full technical breakdown of the G Class trams, exploring their origins, design, local manufacturing, operational benefits, and strategic alignment with Victoria’s transport vision.

Model Origins and Platform

The G Class is based on Alstom’s globally successful Flexity 2 platform, a tram system already in operation in regions such as Blackpool (UK) and Queensland’s Gold Coast. However, the Melbourne variant is heavily customised, a bespoke solution tailored to the city’s complex, mixed-traffic tram network.

Unlike cities with grade-separated light rail systems, Melbourne’s trams operate amidst regular vehicular traffic. This environment requires trams to be robust, safe, and capable of tight cornering and frequent stops. While it shares technological DNA with the Flexity Swift (the basis of the current E Class trams), the G Class signifies a significant leap in form, function, and operational readiness.

Model Origins and Platform

One of the most distinct changes is the re-engineered front nose module, unique among the Flexity 2 family. The modification serves dual purposes:

• Modular crash repair: Designed to allow easy replacement of damaged sections, significantly reducing downtime and repair costs.
• Pedestrian safety: Enhanced crumple zones and design geometry minimise the severity of accidents in Melbourne’s urban environment.

Adaptability and Infrastructure Compatibility

At 25 metres long, the G Class trams are 8 metres shorter than their E Class predecessors, making them compatible with a wider range of routes and reducing the need for costly infrastructure upgrades. This enables:

• Broader network deployment:
• Optimised depot utilisation
• Improved cornering on tight urban curves

The reduced length improves fleet flexibility and ensures operational efficiency in corridors where larger vehicles would struggle.

Three-Part Articulated Design

The G Class consists of:

• Two end modules: Each mounted on a swivelling bogie for improved manoeuvrability.
• A central short module: Housing the pantograph on a fixed wheelbase.

This tri-module configuration allows a fully low-floor central section and improved accessibility for prams, wheelchairs, and mobility aids.

G-Class Tram Interior Space and Accessibility Enhancements

• Raised bogie seating zones: Positioned above wheels to optimise use of space.
• Two-tone flooring: Improves visibility and enhances passenger flow.
• Low-profile articulation handrails: Featuring a “whisk” design for multiple grip points without visual clutter.
• Cab-end vestibule doors: Single-leaf entry doors at both ends, unlike the E Class, improving passenger circulation and access in peak times.
• Priority seating: Intelligently placed near vestibule areas for easier access and usability.

These design elements reflect a deliberate focus on inclusive, human-centred transport design, aligned with accessibility legislation and user experience priorities.

G-Class Tram Locally Built in Dandenong

The G Class trams are being manufactured at Alstom’s Dandenong factory, previously operated by Bombardier and originally established by Commonwealth Engineering (Comeng). The site has a rich history in Victorian rail innovation, having produced:

• Z, A, B, and E class trams
• Comeng suburban trains
• V/Line VLocity regional units

This local production not only supports regional employment but aligns with Victoria’s Local Jobs First policy, ensuring local supply chain participation and knowledge retention within the manufacturing sector.

Depot Rollout Plan

• Essendon Depot: Initial G Class trams to operate on routes 57, 59, and 82.
• Maidstone Depot: A brand-new facility near Highpoint Shopping Centre, designed to accommodate growing fleet needs.
• Future expansion: Kew and Southbank depots are slated for further integration as production scales.

As newer trams enter service, B Class vehicles displaced from these depots will replace aging Z and A Class stock across the network.

SMEs in Australia are integral to the G Class tram project through their involvement in producing key components and technological solutions. Their contributions go beyond just assembling parts, they bring expertise in niche manufacturing areas and provide a level of agility and flexibility that larger companies might not be able to match.

• Manufacturing Components: SMEs in industries such as metal fabrication, electronics, and mechanical engineering supply vital components for the trams. For example, parts such as trams’ chassis, doors, seating systems, and control systems are often manufactured by smaller, highly specialised businesses.
• Specialised Materials: Smaller manufacturers provide customised materials and parts that meet the precise specifications required for the G Class trams. This includes lightweight metals, advanced polymers, and high-strength materials used to reduce the weight of the trams while maintaining durability and safety.
• Technical Expertise: SMEs also contribute to the engineering design of key systems, including electrical systems, automation technologies, and battery systems for hybrid-electric trams. These companies play an important role in the integration of various systems to ensure they work seamlessly within the tram.

Copamate’s Role in the G Class Tram Project

1. Design and Manufacture of Jigs and Fixtures

Copamate specialises in the design and manufacture of jigs and fixtures tailored to the specific needs of the New Generation Tram project. These bespoke solutions are essential for ensuring precise alignment, efficient assembly, and optimal performance of tram components during the manufacturing process.

By providing these specialised tools, Copamate supports the overall efficiency and quality of the tram production process.

2. Support for Local Manufacturing

The G Class trams are being built with at least 65% local content, supporting up to 1,900 local jobs across manufacturing, construction, and the supply chain.

Copamate’s involvement in providing locally manufactured jigs and fixtures contributes to this local content, reinforcing the project’s commitment to supporting the Victorian economy and workforce.

3. Expertise in Rail Industry Components

With over three decades of industry experience, Copamate is an ISO and IRIS certified supplier of train and tram parts. The company has a wide range of products for the rail industry, including components for trams.

This expertise ensures that Copamate’s contributions meet the high standards required for public transport infrastructure.

Battery Integration and Regenerative Braking

The G Class is Melbourne’s first tram to include onboard battery systems, which bring several strategic benefits:

• Reduced peak current draw: Less strain on electrical substations, enabling broader network expansion without infrastructure upgrades.
• Energy efficiency: Capable of regenerative braking, returning energy to the grid or reusing it onboard.
• Lower energy consumption: Estimated 30–40% energy savings per passenger compared to E Class trams.

These advancements are critical for long-term network sustainability and support Melbourne’s ambition to reduce transport-sector emissions.

Melbourne’s next generation trams are more than just a modern upgrade, they represent a key milestone in the state’s transition to a cleaner, more energy-efficient public transport future.

With design innovations geared toward minimising environmental footprint, the G Class supports Victoria’s net-zero emissions goals and broader commitments to sustainable infrastructure.

G-Class Tram Energy Efficiency Through Regenerative Braking and Battery Storage

One of the most transformative environmental features of the G Class is its onboard battery storage system, a first for Melbourne’s tram network. These high-capacity batteries enable regenerative braking, where kinetic energy generated during braking is captured, stored, and reused rather than wasted as heat.

Key Benefits of Regenerative Braking and Battery Integration

• Reduced electricity consumption: Energy harvested during braking can power onboard systems or assist in re-acceleration, reducing draw from the overhead network.
• Lower peak load on substations: The battery system helps balance electrical demand, especially during peak travel times, which delays or eliminates the need for costly power infrastructure upgrades.
• Enhanced grid stability: Trams can operate more consistently and efficiently across routes without the risk of overloading the grid.

This regenerative technology contributes to an estimated 30–40% energy savings per passenger when compared to the E Class trams, marking a substantial reduction in operational carbon emissions.

By constructing the G Class fleet locally in Dandenong at the Alstom facility, Melbourne is cutting down the embodied emissions typically associated with overseas transport and logistics. Local sourcing of materials, reduced transportation miles, and onsite quality control help lower the lifecycle carbon footprint of each tram.

Positive Impacts of Localised Production

• Supports the circular economy by engaging local supply chains.
• Reduces international freight emissions, particularly from long-haul sea or air cargo.
• Improves environmental oversight, as manufacturing can align directly with Victoria’s environmental regulations and best practices.

The G Class trams incorporate lightweight composite materials and recyclable metals wherever possible. These reduce vehicle mass, contributing to overall efficiency, and simplify disassembly and recycling at the end of the tram’s life.

Circular Design Principles in Action

• Modular construction enables easy replacement of components, extending tram lifespan and reducing waste.
• Standardised parts allow for parts harvesting and reuse across different tram generations.
• Reduced environmental disruption through easier depot and maintenance integration, with less reliance on heavy retrofitting or demolition.

Every G Class tram is capable of carrying up to 150 passengers under crush load, equating to removing over 100 cars from inner-city roads during peak hours. This shift leads to:

• Reduced road congestion
• Lower vehicular emissions (especially from private petrol and diesel vehicles)
• Improved urban air quality

These factors directly support Melbourne’s goals around urban liveability, green transport corridors, and climate adaptation strategies outlined in Plan Melbourne and other long-term planning frameworks.

As older Z and A Class trams, many of which are over 40 years old, are retired, the network’s overall efficiency and environmental footprint will dramatically improve. Compared to their predecessors, G Class trams:

• Operate more quietly (reducing noise pollution in urban environments)
• Emit zero direct emissions (as they are fully electric)
• Use sustainable cooling and lighting systems (such as LED lighting and energy-efficient HVAC units)

Alphabetically, one would expect the new tram class to be designated “F.” However, practical and symbolic reasons led to the choice of “G”:

• G is the 7th letter, marking the 7th tram generation.
• Fleet numbers begin with 7 (e.g., the prototype is #7000).
• “G” invokes positive associations: Good, Great, Green.
• “F” could be seen as problematic in public discourse or casual references.

This naming strategy, while subtle, reflects brand-conscious planning that aligns public perception with the forward-looking values of the new fleet.

The modular Flexity 2 design supports the future addition of extra segments. A five-module G Class configuration could eventually accommodate higher passenger volumes through:

• A second centre module
• Suspended intermediate sections

While not immediately planned, this potential ensures long-term value and flexibility, future proofing the investment as demand grows.

The G Class tram project is more than a fleet replacement, it is a strategic investment in Melbourne’s transport future. With its modular design, sustainability credentials, accessibility improvements, and local manufacturing focus, the G Class represents the best of:

• Engineering innovation
• Operational efficiency
• Social inclusion
• Environmental responsibility

Government bodies, urban planners, and commuters alike should see this initiative as a template for modern, adaptive transport planning. As these trams begin to roll out across the network, Melbourne reinforces its place as the home of the world’s largest operational tram system, modernised for the next century.

The G Class initiative aligns with Victoria’s goals under the Big Build transport program, complementing major investments in:

• Level crossing removals
• Suburban Rail Loop
• Metro Tunnel project
• Sustainable infrastructure goals under Victoria’s Climate Change Strategy

Together, these efforts point to a cohesive, long-term mobility strategy, where rolling stock investments, like the G Class trams, become enablers of broader urban transformation.