Tag: battery system and pack production

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Hybrid vehicles return to North America’s production lines as automakers rethink strategy

Automakers that once aimed to skip hybrids and go straight to electric vehicles are now reintegrating hybrids into their North American line-ups. Building “half-and-half” cars is proving technically tricky but strategically worthwhile.

Ilkhan Ozsevim

UK vehicle production slips behind global leaders as China and North America accelerate EV manufacturing, trade alignment and industrial policy

AMS explores why the structural forces behind Britain’s vehicle production are in decline, contrasting it with the strategic clarity and industrial momentum driving EV investment across North America, and preeminently.

Ilkhan Ozsevim

Automotive expert Tunç Kip says human-machine interfaces are essential in boosting flexibility, quality, and performance in global automotive manufacturing

From the factory floor to upstream design, digital human-machine interfaces are enabling smarter, leaner, and more flexible vehicle production - but humans need to be at the centre of gravity for it to work.

Ilkhan Ozsevim

How Arno Güllering wants DRÄXLMAIER Group to harness shopfloor visualisation and genAI in production and maintenance

The tier-1 supplier has established a highly connected production and logistics network, with a strong emphasis on data visualisation and a roadmap for AI. But to stay competitive and resilient, COO Arno Güllering wants to ensure both plants and HQ have a mindset ready to embrace change.

Christopher Ludwig

China’s rapid rise in electric vehicle adoption is reshaping global auto manufacturing, forcing Western OEMs to rethink costs, portfolios and consumer strategies

As China leads the global EV transition with record-breaking sales and technology advances, Western carmakers face mounting pressure to cut costs, target regional needs and rethink loyalty strategies.

Ilkhan Ozsevim

China’s rare earth magnet export ban threatens global EV and automotive manufacturing, as US, European and Asian carmakers scramble to secure critical materials

The global automotive sector is facing renewed disruption as China tightens control over exports of heavy rare earths and magnets. With EV powertrains and chips at risk, OEMs are now racing to diversify supply.

Ilkhan Ozsevim

Stellantis and Factorial Energy validate breakthrough solid-state batteries with fast-charging FEST technology and target 2026 EV demonstration fleet integration

Stellantis and Factorial Energy have validated high-density, fast-charging solid-state battery cells. Their collaboration now aims at optimising battery packs for efficiency and introducing a 2026 EV demonstration fleet.

Ilkhan Ozsevim

Honda’s $1bn redevelopment of its Ohio plants sets a global precedent in integrating EV, hybrid and ICE production with smart manufacturing and supplier transformation.

Honda North America’s upgraded Ohio operations will be its template for flexible production of ICE, hybrid and electric vehicles on a single line. Project lead Mike Fischer speaks to AMS about the goals, planning and execution behind this major production shift.

Nick Holt

As VW cuts back in Germany, Slovakia and Spain emerge as new pillars of cost-effective and future-focused production across Europe

As VW’s traditional German plants face uncertainty, its long-established facilities in Bratislava and Pamplona are stepping into the spotlight—producing top-selling models and gearing up for a new era of electric vehicles.

Timo Gilgen

Lucid acquires Nikola’s former Arizona facilities and offers jobs to over 300 former employees as it scales up EV manufacturing and testing operations

Lucid has struck a deal to acquire two former Nikola facilities in Arizona, adding nearly 900,000 sq. ft to its production and testing capacity and offering jobs to over 300 ex-Nikola workers as it scales EV production

Ilkhan Ozsevim

Webasto and Cylib forge sustainable partnership to recycle used batteries and secure critical raw materials

Automotive supplier Webasto has partnered with battery recycling scale-up Cylib to recover lithium, graphite and other key materials. The collaboration will help Webasto meet EU sustainability targets while securing critical resources for Europe’s electrification push.

Ilkhan Ozsevim

Honda to source hybrid vehicle batteries from Toyota’s new US plant as tariff threats and shifting EV policies force Japanese carmakers to rethink their supply chains

Honda will source hybrid batteries from Toyota’s $14bn US factory starting in 2025, as rising tariffs under Trump and declining EV incentives prompt Japanese carmakers to reinforce local supply chains

Ilkhan Ozsevim

JLR expands EV production with 150 new UK roles supporting Range Rover Electric and next-generation electric vehicle manufacturing

JLR is expanding its UK workforce with 150 new maintenance roles to support EV production. With Solihull and Wolverhampton at the heart of its transformation, the company is investing in people, technology and electrification.

Ilkhan Ozsevim

Global battery industry enters new phase as demand surges and prices drop below key cost threshold for Electric Vehicles

The global battery industry has entered a transformative phase. EV demand is pushing annual battery needs past 1TWh, while prices fall below a key cost threshold. China remains dominant, but market shifts and consolidation are poised to reshape supply chains worldwide.

Ilkhan Ozsevim

IONETIC strengthens leadership with Steve Boulter as CTO to drive innovation and growth in EV battery pack technology

IONETIC has appointed Steve Boulter as Chief Technology Officer to lead the expansion of its Arc technology stack, driving cost-effective and scalable battery pack solutions for niche vehicle manufacturers.

Ilkhan Ozsevim

BMW’s Neue Klasse redefines electric mobility with advanced Software-Defined Architecture and high-performance energy management

BMW’s Neue Klasse redefines electric mobility with a software-centric vehicle platform, high-voltage 800V battery technology and four advanced computing modules. A new era of efficiency, flexibility, dynamic performance and seamless energy management is emerging?

By Andrea Hoffmann-Topp

Solving EV battery pack development, cost and production challenges

James Eaton, CEO of IONETIC, discusses the evolving landscape of EV battery pack development and production, focusing on the challenges facing low-volume manufacturers. Eaton shares insights into the importance of cost optimisation, flexible manufacturing, and overcoming the unique challenges of electrifying commercial vehicles such as buses.

Nick Holt

Rivian strengthens EV ambitions with $6.6B federal loan to develop advanced manufacturing facility in Georgia

Rivian’s $6.6 billion loan from the US Department of Energy bolsters its ambitious plans for a key Georgia manufacturing hub. The 9 million sq. ft facility will increase production of next-gen EVs, foster innovation and boost regional production.

Ilkhan Ozsevim

Coventry and Warwick Gigapark aims to transform UK EV battery production amid competition and policy pressure

The Coventry and Warwick Gigapark seeks to anchor the UK’s position in Electric Vehicle (EV) battery Production. With 5.7m sq.f of industrial space, incentives, and a central location, it’s a critical response to ZEV mandates and global competition.

Ilkhan Ozsevim

BMW Group strengthens circular economy through SK tes battery recycling, advancing sustainability in Europe and beyond

The BMW Group has launched a partnership with SK tes to recycle high-voltage batteries across Europe. This closed-loop process reclaims critical materials such as cobalt, nickel, and lithium, boosting sustainability and reducing supply chain risks.

Ilkhan Ozsevim

Mazda to build module pack plant for cylindrical lithium-ion batteries

Mazda’s new plant will be located in Iwakuni City, Japan and will produce battery packs for its new EVs.

Nick Holt

Ford’s Halewood facility begins production of electric drive units strengthening the UK’s role in EV manufacturing

The electrification of Ford’s Halewood plant is more than just a strategic pivot; it’s a testament to the company’s vision for sustainable automotive manufacturing. By producing over 420,000 electric drive units annually, the plant will power Ford’s top-selling EV models and support Europe’s transition to zero-emission vehicles.

Ilkhan Ozsevim

Volkswagen Chattanooga and Christopher Glover: a masterclass in flexible manufacturing in North America

As Volkswagen celebrates its 75th year in the US, its Chattanooga plant exemplifies a flexible manufacturing model that integrates electrification, workforce innovation, and supply chain resilience. With Chris glover as EVP, the plant has become a benchmark for industry transformation.

Ilkhan Ozsevim

Exclusive: How Henkel is co-developing the EV batteries of the future at its Battery Engineering Center

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with HenkelHenkel, a global leader in adhesives, sealants and functional coatings, inaugurated its revolutionary Battery Engineering Center (BEC) within its Inspiration Center Düsseldorf (ICD) in November last year. Henkel invited AMS as its first visitor, to take a tour of the Battery Application Center (BAC) and Battery Test Center (BTC) within the BEC and the innovations happening inside.

AMS

Watch: Henkel invites AMS for an exclusive look inside its Battery Engineering Center

AMS

Honda sets up a demonstration production line for all-solid-state batteries

Honda’s demonstration production line will support development for the mass production of solid-state batteries.

Nick Holt

BMW reinforces EV production quality with first phase go-ahead for new Wackersdorf battery testing centre in Germany

BMW’s Wackersdorf facility, now home to an advanced battery testing centre, highlights the automaker’s push towards sustainability and precision in electric vehicle production. The €100 million ($105.65m) investment underscores BMW’s commitment to innovation.

Ilkhan Ozsevim

Henning Habicht appointed Head of Volkswagen Chattanooga Operations

Habicht takes over from Chris Glover, who will retire in January 2025 after more than three decades with Volkswagen, including a three-year stint at Chattanooga.

Nick Holt

HORSE’s smart factory model sets new standards in digital powertrain production, leveraging cobotics, virtual twins, and real-time data for efficiency and sustainability

HORSE is pioneering a smart factory approach for powertrain production, integrating cobotics and virtual twins in a fully digital environment that adapts to changing demands, enhancing both efficiency and sustainability across its global operations. CTO Julien Faure, and CPEO, Antonio Vaz expound…

Ilkhan Ozsevim

Change is the only constant for Volkswagen Chattanooga EVP Christopher Glover

The head of Volkswagen’s US plant operations is managing market and technology complexity through flexible facility design, practical digitalisation, training and engagement with workers. He speaks to AMS ahead of a keynote presentation at AMS Evolution North America in Michigan.

Christopher Ludwig

SAMES’ solutions: precise assembly processes for battery packs

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with SamesAs the electric vehicle (EV) market grows, the need for efficient and safe battery pack assembly intensifies. Benoit Batllo from SAMES shares how the company tackles challenges in applying critical materials like dielectric coatings, fire protection coatings, and thermal conductive adhesives (TCAs)

AMS

How BYD’s partnership with Apple shaped the future of EV battery technology

Apple’s secret partnership with Chinese automaker BYD focused on developing long-range EV batteries. While Apple’s car project was shelved, BYD’s Blade battery benefited from the collaboration, becoming a key driver of its success in the competitive EV market.

Ilkhan Ozsevim

EV batteries – Increasing quality and reducing costs

A new eBook from Hexagon examines how AI and smart factories are revolutionising EV battery manufacturing, helping Europe and North America catch up with China.

Hexagon Manufacturing Intelligence

General Motors shifts EV battery strategy by scrapping Ultium name as it balances EV ambitions with strong ICE demand

The carmaker has announced it is making a strategic shift by dropping its Ultium battery branding as it reconfigures its EV business. While reaffirming its commitment to electric vehicles, GM also continues to invest in internal combustion engines to meet demand.

Ilkhan Ozsevim

Hyundai, Kia, Hyundai Steel, EcoPro BM partner for LFP battery breakthroughs

The Korean consortium aims to eliminate the precursor step in LFP battery cathode material production, reducing emissions and costs. The project, supported by the Korean government, focuses on developing high-purity iron powder and directly synthesised LFP cathode material for improved battery performance.

Ilkhan Ozsevim

Mexico’s automotive industry is a balancing act between foreign investment and domestic concerns

While the US government encourages domestic production, Mexico continues to attract foreign automotive investment. The trend is particularly evident in the arrival of Chinese manufacturers, poised to have a significant impact on regional production.

Ian Henry

Canada – Mixed fortunes for production operations

Canadian vehicle and component production operations are feeling the impact of slow EV sales. However, the country has many assets making it attractive to investment, especially in battery production.

Ian Henry

Valmet Automotive’s battery business to become an independent company

Valmet Automotive is making its Electric Vehicle Systems business an independent company with its own leadership. The company says it plans to target markets beyond automotive.

Marcus Williams

Ford revises EV strategy and boosts hybrid production

Ford cancels planned three-row EV SUV, delays opening of Tennessee EV plant and realigns US battery cell production.

Nick Holt

Korea’s LG, SK On and Samsung lead Prismatic battery revival impacting Electric Vehicles and Automotive Production

The prismatic battery is making a comeback, with Korean battery giants leading the charge. Offering advantages in safety and cost, this technology could have lasting implications for the Electric Vehicle, battery, and automotive production landscape.

Ilkhan Ozsevim

Stryten Energy and Dragonfly Energy agree to electrify North American automotive production

A strategic partnership between Stryten Energy and Dragonfly Energy will see the ’Battle Born Batteries’ brand enter new consumer markets, while bolstering domestic lithium battery production.

Ilkhan Ozsevim

Despite industry fears, global EV sales reach record highs in 2024 and remain on an upward trajectory

How will slowing growth in EVs impact auto industry investment strategies? As the industry navigates challenges from rising costs and charging infrastructure gaps, to consumer range anxiety and rising competition, Daniel Harrison explodes some EV myths.

Daniel Harrison

Nissan and Honda agree to joint research for next-gen SDV platform

The two companies have agreed to joint research in fundamental technologies next-generation software-defined vehicles (SDVs).

Nick Holt

Ford bolsters battery manufacturing with Chris White’s new global role

Ford promotes Chris White to Chief Engineer, Global Battery Manufacturing Engineering. With over 30 years of experience, White will drive Ford’s global EV battery strategy, enhance European operations, and develop cutting-edge manufacturing processes.

Ilkhan Ozsevim

Powering the future: Top 5 EV battery chemistries and formats across the world

With batteries underpinning the electrification journey, we take a look at the battery chemistries and architectures driving the change.

AMS

How Ford’s Marc Dugas is supercharging battery pack assembly using the POSIWID system

In this Q&A we explore how Marc Dugas, Ford’s Technical Specialist for Battery Pack assembly, uses a little-known systems thinking heuristic called POSIWID, (the Purpose Of the System Is What It Does) to supercharge battery pack assembly

Ilkhan Ozsevim

European battery production needs greater speed and agility

Exhibitors at this year’s Battery Show in Stuttgart shared insights into EV and battery production challenges and how the industry needs to adapt with greater speed.

Nick Holt

Electric Dreams: Tesla’s gigafactory network and EV battery production blueprint

From Fremont to Berlin, Tesla’s gigafactories are the drivers in its goal to lead the EV market. Each site plays a crucial role in electric vehicle and battery innovation, ensuring Tesla meets global demand and maintains its lead in the electrification race.

Ilkhan Ozsevim

Ampere supports Renault Group with LFP technology and cell-to-pack solutions

Ampere will integrate LFP (Lithium Iron Phosphate) technology to complement NCM batteries (Nickel Cobalt Manganese) and create a European value chain.

Nick Holt

Volkswagen’s Traton eyes third European battery plant to meet Electric Vehicle demand

Traton Group, Volkswagen’s commercial vehicle arm, considers a third battery assembly plant in Europe to support rising electric truck demand. Potential locations include Germany, Poland, and the Netherlands. This move aligns with the EU’s carbon reduction roadmap and Traton’s goal of 50% zero-emission vehicle sales by 2030.

Ilkhan Ozsevim

Designing manufacturing systems for flexibility and scalability

Comau discusses assembling e-drives, developing battery manufacturing solutions, and collaborations with universities for next-generation cells.

AMS

Stellantis and French energy expert CEA collab on next-gen battery cell tech

In a five-year collaboration, automaker Stellantis and France’s CEA will develop next-gen EV battery cells. The partnership targets advanced technology with improved performance, durability, and sustainability, potentially leading to more affordable electric vehicles.

Ilkhan Ozsevim

HORSE announces next-generation Range Extender powertrains

HORSE has introduced innovative Range Extender powertrains for passenger and light commercial vehicles. Offering a 200km electric range plus an additional 600km from an onboard engine, this technology reduces battery size by over 50%, cutting costs and weight.

Ilkhan Ozsevim

Q&A with Patrice Haettel: CEO of powertrain technology company HORSE

Renault’s powertrain tech company, HORSE, has begun mass-producing the Power Electronics Box (PEB); crucial for HEVs and PHEVs. The redesigned PEB boosts performance by managing Emotors more efficiently. Here’s CEO, Patrice Haettel on electrification and more.

Ilkhan Ozsevim

Breaking down silos: the necessity for co-creative collaboration

The Design4Production event in Munich proved that collaboration between is key to success across automotive production, engineering and design. The topic was present across every single session in one form or another. Here are the highlights of the theme…

Ilkhan Ozsevim

Driving Innovation: The 3rd International Automotive Wire Harness Conference Returns to Detroit in 2024

Our presentations will focus on showcasing solutions, strategies, and tools for a range of topics such as electrification, advanced E/E architecture, functional safety, sustainability, mass reduction, high-speed data networks, commercial vehicle unique topics, simulation, and labor/complexity reduction through manufacturing automation and digitalisation.

AMS

Ford Otosan manufacturing for an economy in transition

Ford Otosan has upgraded its manufacturing facilities in Turkey to ensure the Transit is ready for an electrified future

Mark Smyth

Rivian secures $827m funding, plans expansion and brings in Javier Varela as new COO

Rivian secures $827m in public funding from Illinois Department of Commerce & Economic Opportunity despite announcing 10% workforce cuts earlier this year. Javier Varela appoitned new COO ahead of R2 production

Ilkhan Ozsevim

Toyota invests $1.4B in US manufacturing for new BEV SUV

With a focus on sustainability and job creation, Toyota’s investment in its Princeton facility in Indiana aims to solidify its position in the electrification market, adding up to 340 new jobs and bolstering its long-standing partnership with the state

Ilkhan Ozsevim

Renault subsidiary, HORSE, kicks off Power Electronics Box production

Power Electronics Box (PEB) production at the Aveiro facility in Portugal promises enhanced scalability and efficiency in meeting the rising demand for hybrid vehicle components.

Ilkhan Ozsevim

Impacts of global geopolitics on European production

Geopolitical influences on the automotive manufacturing sector are intensifying and becoming ever more powerful. European trends cannot be looked at in isolation; their impact on the ground in Europe have their roots in wider global factors…

Ian Henry

OEMs jointly develop green battery prototypes with Henkel

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Henkel More OEMs are looking to build their own EV batteries in-house to streamline production and logistics and have more visibility on costs and efficiencies. In a fast-paced competitive market where technologies evolve and overtake one another quickly, carmakers are keen to keep their progress under wraps – particularly when it comes to battery prototypes. But they are making an exception for the purpose of recycling and repair, according to Henkel’s battery sustainability expert, Philipp tho Pesch.

AMS

How BMW is ramping up its circular production and sustainability principles as it drives towards electrification

BMW’s Dr. Irene Feige, Head of Climate Strategy and Circular Economy says that circular economy is becoming central to BMW’s automotive production landscape, part of its wider push for sustainable production and supply chains.

Ilkhan Ozsevim

Google’s Clausen takes GM manufacturing mantle as EVP Johnson retires

GM’s longtime EVP Gerald Johnson announces retirement after 44 years. Clausen appointed new EVP, Abbott to step down due to health. Leadership transition underway for manufacturing and software divisions.

Ilkhan Ozsevim

“Our future viability is not a given”: BMW Leipzig’s plant manager Petra Peterhänsel

Despite the crises, the BMW plant in Leipzig is optimistic about the future: in an interview, plant manager Petra Peterhänsel explains how investments in electrification and automation should contribute to a rosy future for the location

Yannick Tiedemann

Ronja Schmiedchen

DESIGN4PRODUCTION brings together leaders in automotive production, design, and engineering

Explore the future of automotive design and manufacturing at Design4Production in Munich on 15 May and join leading designers, engineers and production leaders on Automotive design and manufacturing experts as they discuss how to accelerate innovation, efficiency and sustainability.

AMS

How Farasis will bridge the EV battery gap in Europe

The Chinese battery manufacturer’s new European general manager, Marcel Brömlage, will lead an evolving strategy in the region including increasing engineering and acquisition capabilities, and targeting automotive as well as non-automotive customers to support the growth strategy for the Siro joint venture and Farasis group.

Christopher Ludwig

BYD – Aiming for the top

In this new monthly column, Ian Henry of AutoAnalysis looks at a major automotive development and places this within its broader context, asking what this means for the industry. To kick this series off, Ian looks at BYD (Build Your Dreams), the Chinese company which – if it succeeds – will be a major player in Europe within the next few years; it is already the largest EV manufacturer in the world

Ian Henry

Is sodium-ion the future of battery tech? - Stellantis Ventures all-in on France-based battery tech startup, Tiamat

The battle of battery tech continues. Stellantis is investing in Tiamat’s sodium-ion tech, eyeing cost-effective, sustainable energy, while, BMW pursues Solid Power’s solid-state batteries for efficiency gains. Which chemical composition will lead? Will any?

Ilkhan Ozsevim

BMW Munich plant to go full electric with Neue Klasse and revamped, digital production system

BMW’s home plant will produce only EVs by 2027, with much of the century-old factory rebuilt to meet new levels of efficiency and digitalisation, without missing a beat of ongoing production.

Christopher Ludwig

Hyundai, Kia and Gore collaborate for fuel cell electric commercial vehicles

The agreement between Hyundai, Kia and Gore is future-focused, working towards seizing market shifts that hinge on battery tech developments. The joint effort focuses on polymer electrolyte membrane (PEM) technologies and expands the 15-year-long tripartite unity to develop next-gen hydrogen-fuel battery tech as demand grows.

Ilkhan Ozsevim

Vietnam’s VinFast announces Indian market penetration with $500m EV plant and eyes Europe for its next move

Vinfast accelerates global expansion plans by inking historic MoU with Tamil Nadu, India, for major EV investment signalling shift in regional mobility. The Vietnamese EV producer targets 150,000 EVs and eyes 50 markets on its horizon, including Europe.

Ilkhan Ozsevim

The state and stipulation of automotive production: Retrospect 2023 to prospect 2024

Using 2023 as a launchpad into the coming trends of 2024, we take a dive into the coming automotive production trends set to shape the industry

Ilkhan Ozsevim

AMS Winter 2023/24 – BMW’s battery boost

Our Winter digital edition takes an in-depth look at how OEMs are getting to grips with developing and manufacturing new electric vehicles and powertrains

AMS

How battery and electric motors and EVs are reshaping the European automotive supply chain

The automotive industry is in a major shift with EVs reshaping the supply chain. Challenges and opportunities include replacing traditional components tied to combustion engines, new players in the battery market, disruptors facing tariffs, and the looming influence of China in Europe; all adding new layers of complexity.

Ian Henry

How Europe’s Big 3 (Volkswagen, Stellantis, Renault) are evolving their manufacturing arrangements and production strategies in the European automotive industry as electrification takes hold

As the automotive industry in Europe undergoes a seismic shift from internal combustion engines (ICE) to electric vehicles (EV), major players like Volkswagen, Stellantis and Renault are navigating complex changes in their production strategies.

Ian Henry

ONE’s innovative strategies in chemistry, manufacturing and sustainability are transforming EV safety

AMS explores Our Next Energy’s (ONE) innovative approach to EV battery safety. The company’s CEO and founder, Mujeeb Ijaz, discusses manufacturing solutions to eliminate thermal runaway, enhance range, and optimise sustainability

Martin Kahl

Skoda auto unveils next chapter with production launch of fourth-generation superb at Bratislava plant, alignment with visionary Beta+ project marks a transformative milestone

Efficiency meets innovation as Skoda’s flagship Superb starts production in Bratislava with goals to set new standards in automotive excellence and sustainability.

Ilkhan Ozsevim

Advanced materials application for EV battery production

Coatings, adhesive and sealant application equipment, plays a crucial role in enabling the efficient implementation of advanced materials in the EV battery manufacturing process. SAMES discusses how its technologies and experience can be instrumental in ensuring the quality and safety of EV batteries.

SAMES

AESC and Umicore deal bolsters BMW’s North American EV battery supply chain

Battery cell manufacturer AESC has inked a deal with Umicore, a leader in battery materials production, to secure a local source of cathode active battery materials in North America.

Ilkhan Ozsevim