Honda Motor is ushering in a new era of manufacturing in an unexpected location—Ohio. For the first time in its 75-year history, the Japanese automaker is making groundbreaking advancements outside of its home country.
This year, Honda is finalizing more than $1 billion in investments in Ohio, an increase from the previously announced $700 million.
The upgrades include the installation of six high-pressure “giga presses,” a technology popularized by Tesla, and a new “cell” manufacturing system for its next-generation electric vehicle (EV) battery cases.
Honda’s growing EV hub in Ohio, which includes a separate $3.5 billion battery plant, will serve as the model for its global manufacturing operations.
The Marysville Auto Plant will be capable of assembling traditional gas-powered vehicles, hybrids, and EVs on the same production line, company officials revealed during a tour of the facility.
“The Honda EV hub in Ohio is establishing the global standard for EV production for people, for technology and for processes,” said Mike Fischer, Honda’s North American lead for battery-electric vehicle projects.
“As we expand EV production regionally and globally, this is the footprint and the characteristic performance that will be used.”
A Shift in Honda’s Manufacturing Strategy
Historically, major manufacturing innovations at Honda originated in Japan before expanding to other global facilities.
However, the Ohio investments, initially announced in October 2022, align with the Biden administration’s push to reshore manufacturing. They also hold strategic importance as President Donald Trump considers increasing tariffs on imported goods, including automobiles.
In 2024, Honda produced over 1 million vehicles at its five U.S. assembly plants, with approximately 64% of them sold domestically and the rest exported. The company also operates one assembly plant in Mexico.
Once the upgrades are complete, Honda’s Marysville plant—located outside Columbus—will have an annual production capacity of around 220,000 vehicles.
The 4 million-square-foot facility currently manufactures multiple Honda and Acura models. Later this year, it will begin producing the all-electric Acura RSX crossover, marking the first Honda-made EV.
Honda’s Late But Aggressive EV Push
Compared to its competitors, Honda was slow to enter the EV market. Currently, it sells two all-electric crossovers in the U.S.—the Honda Prologue and the Acura ZDX—but both are produced by General Motors in Mexico.
However, Honda is now accelerating its EV plans. Following the Acura RSX, the company will launch the Honda 0 SUV and Honda 0 Saloon, two EV prototypes unveiled at CES 2025 in Las Vegas.
Advanced Battery Manufacturing and Gigacasting
The aluminum battery packs for Honda’s next-generation EVs will be produced at its engine plant in Anna, Ohio—the automaker’s largest engine facility worldwide. Since its opening in 1985 as a modest rectangle-shaped building, the complex has expanded to over 2.8 million square feet.
Honda Plant
“We’re establishing this large aluminum production technology for all Honda,” said Tim Stroh, Honda’s EV battery case project leader. “The goal here is to roll that out to other products, other factories across the world.”
To produce battery packs and other EV components—potentially including engines in the future—Honda is installing six massive 6,000-ton high-pressure die-casting machines.
These machines will use “gigacasting,” a technique made famous by Tesla, which can reduce manufacturing costs by eliminating the need to weld multiple body parts. Honda’s current presses in Ohio operate at a maximum of 3,500 tons.
Once the battery packs are cast, they will be sent from Anna to Marysville and other Honda plants, where battery cells from Honda’s joint venture with LG Energy Solution will be installed before the packs are integrated into EVs.
A New Era of Vehicle Assembly
To integrate battery cells and packs at Marysville, Honda is implementing nearly 60 flexible manufacturing “cells,” or zones, for battery assembly.
Unlike traditional assembly lines—where vehicles move along a fixed path—this system allows production to occur in parallel zones. This reduces the risk of bottlenecks and ensures that issues in one area do not disrupt the entire line.
“This is considered the second founding for Honda,” said Bob Schwyn, senior vice president of Honda Development and Manufacturing of America. “We’re using the opportunity to reimagine our approach to manufacturing.”
Honda has described its transition to EVs and fuel-cell vehicles as its “second founding.” Despite the slower-than-expected adoption of EVs in the U.S., the company remains committed to its long-term goal of achieving zero environmental impact by 2050. This includes carbon neutrality, clean energy utilization, and resource circulation.
Sustainability and Recycling in Manufacturing
As part of this goal, Honda aims to sell only zero-emission vehicles by 2040. While some automakers have scaled back similar targets, Honda remains committed to its sustainability initiatives.
The company’s Ohio investments include new manufacturing processes to reduce emissions and waste. For example, Honda is using a specialized structural aluminum for its EV battery packs, which can be fully recycled and reused.
“We’re using the opportunity to reimagine our approach to manufacturing and create new value in the area of environmental responsibility,” Schwyn said.
“This includes strategies to recapture our products at end-of-life and then recycle or reuse 100% of the materials, especially finite materials for EV batteries to essentially make new Hondas out of old Hondas.”
By investing in cutting-edge technology, flexible manufacturing, and sustainability, Honda is positioning Ohio as the blueprint for its global EV strategy.
