MARYSVILLE, Ohio — Honda Motor Co. is ushering in a new era of manufacturing in an unexpected yet strategically significant location: Ohio.
The 75-year-old Japanese automaker is finalizing more than $1 billion in new investments across the state this year, an increase from its originally announced $700 million. This investment includes the implementation of six advanced “giga presses,” a technology popularized by Tesla, along with the introduction of a cutting-edge “cell” manufacturing system for electric vehicle (EV) battery cases.
Honda’s rapidly evolving EV hub in Ohio, which also includes a separate $3.5 billion battery plant, is set to become the cornerstone of the company’s global manufacturing strategy. The Marysville Auto Plant will serve as a benchmark facility, integrating the production of traditional internal combustion vehicles, hybrids, and EVs on a single assembly line.
“The Honda EV hub in Ohio is setting the global standard for electric vehicle production—enhancing efficiency, innovation, and sustainability,” said Mike Fischer, Honda’s North American lead for battery-electric vehicle projects. “As we scale up EV production both regionally and worldwide, this facility will define the blueprint for our future manufacturing operations.”
Typically, major manufacturing advancements would first be implemented in Honda’s home country of Japan before expanding to U.S. and global facilities. However, Honda is breaking from tradition with its ambitious investment in Ohio, underscoring the state’s growing significance in the company’s global strategy.
A Strategic Investment Amid Policy Shifts
Honda’s $1 billion investment in Ohio, initially announced in October 2022, aligns with the Biden administration’s efforts to reshore manufacturing. This commitment remains crucial amid potential tariff increases on imported automobiles, as proposed by former President Donald Trump.
In 2024, Honda produced over 1 million vehicles at its five U.S. assembly plants, with approximately 64% sold domestically and the remainder exported. The company also operates a single assembly plant in Mexico. Once fully operational, Honda’s Marysville plant—located just outside Columbus—will have an annual production capacity of roughly 220,000 vehicles. This 4-million-square-foot facility currently manufactures various Honda and Acura models and will soon introduce the all-electric Acura RSX crossover, Honda’s first EV built in the U.S.
Accelerating Honda’s EV Transition
Despite its late entry into the EV market compared to competitors, Honda is rapidly expanding its electric vehicle lineup. Currently, the company offers two all-electric crossovers in the U.S.—the Honda Prologue and Acura ZDX—both of which are manufactured by General Motors in Mexico. However, Honda is now taking control of its EV production with the upcoming Acura crossover, followed by the Honda 0 SUV and Honda 0 Saloon EV prototypes, recently unveiled at CES 2024 in Las Vegas.
A critical component of Honda’s EV strategy is its aluminum battery pack production, which will take place at its engine facility in Anna, Ohio. Originally established in 1985 as a small manufacturing site, this plant has since expanded to more than 2.8 million square feet, making it Honda’s largest engine facility worldwide.
Introducing Gigacasting: A Revolutionary Manufacturing Approach
To support its EV production, Honda is implementing cutting-edge gigacasting technology—an industry-shifting method pioneered by Tesla. The company is installing six 6,000-ton high-pressure die-cast machines, capable of producing large vehicle components in a single cast. These machines, each the size of a small house, significantly reduce the need for welding multiple parts together, thereby improving efficiency and lowering per-unit manufacturing costs.
Once cast, the aluminum battery packs will be transported from Anna to Marysville, where battery cells from Honda’s joint venture with LG Energy Solution will be installed before final EV assembly.
A Next-Generation Manufacturing Model
To optimize production, Honda is introducing nearly 60 flexible manufacturing “cells” at its Marysville facility. Unlike traditional assembly lines where production flows in a linear sequence, these modular zones operate in parallel, preventing slowdowns from affecting the entire process. This innovative approach enhances efficiency and adaptability in EV production.
“This is considered the second founding for Honda,” said Bob Schwyn, Senior Vice President of Honda Development and Manufacturing of America. “We’re using this opportunity to reimagine our approach to manufacturing.”
Commitment to Sustainability and Zero-Emissions Goals
Honda has dubbed its transition to electric and hydrogen fuel-cell vehicles as its “second founding.” Despite slower-than-expected EV adoption in the U.S., the company remains committed to its long-term sustainability objectives, including achieving zero environmental impact by 2050. This vision is built around three key pillars: carbon neutrality, clean energy, and resource circulation.
Honda also maintains its goal of exclusively selling zero-emissions vehicles by 2040, even as some automakers scale back their EV ambitions. The company’s Ohio investments include innovative sustainability measures, such as using structural aluminum in battery packs that can be fully recycled and repurposed.
“We’re reimagining manufacturing not just for efficiency, but for environmental responsibility,” Schwyn added. “Our strategy includes reclaiming end-of-life products and ensuring that 100% of materials—especially finite EV battery resources—are recycled and reused. The goal is to create new Hondas out of old Hondas.”
Conclusion
Honda’s investment in Ohio marks a pivotal moment in its manufacturing evolution. By integrating gigacasting, flexible production systems, and sustainable practices, the company is positioning itself at the forefront of the electric vehicle revolution. With its Marysville facility leading the way, Honda’s “second founding” is shaping the future of global automotive production.
