Bühler’s megacasting solutions set to enhance Honda’s EV production

Swiss technology leader Bühler Group delivered its first megacasting solutions to Honda Motor Company Ltd., marking a significant step in the Japanese automaker’s electric vehicle (EV) production push. Honda has invested in multiple Bühler Carat 610 die-casting machines to ramp up manufacturing across its North American network and meet growing customer demand. One of these advanced casting cells is being used for research and development in Japan, while the rest will be deployed at Honda’s Anna Engine Plant in Ohio, USA.

Honda is investing in growing its EV production operation in North America to strengthen its supply system and its ability to prepare for a continued increase in demand in the region. The company is establishing an EV Hub in Marysville, Ohio, which will begin production of EVs alongside existing internal combustion engines and hybrid-powered vehicles this year. This expansion of capabilities in North America supports its vision to make battery-electric and fuel-cell electric vehicles represent 100 per cent of its vehicle sales by 2040.

As part of this strategic move, Honda is installing several Bühler Carat 610 megacasting machines to cast the cases for its Intelligent Power Units (IPUs). The IPU case will contain the EV battery module and serve as the main frame structure for the floor of Honda and Acura EVs. It will be manufactured at the Anna Engine Plant and then delivered to the EV Hub in Marysville, where the battery modules will be installed.

A Honda representative stated, "The IPU case is much larger than anything Honda has die-cast before. It will be die-cast in two pieces and welded together."

"In-house production of IPUs is the first step for Honda. Bühler is equipped to support Honda in this venture with its experienced process engineers and extensive technological know-how, alongside the advanced Carat 610 die-casting machine, to ensure the successful production of the IPU case."

In October 2024, Honda Motor Co., at a “Honda 0 Tech Meeting 2024” event, stated, “A 6,000-tonne class megacasting (high-pressure, high-precision casting) machine will be adopted to the IPU (battery) case production line, which will significantly reduce the number of parts from more than 60 to 5. In addition, by joining a dedicated IPU case part, which is different for each EV model size, and a common part with FSW technology, a variety of IPU cases can be produced efficiently. This will improve overall production efficiency and limit the required capital investment. Honda will continue to advance these production technologies, including expanding its application to large aluminium casting body frame parts in the future.”

Cornel Mendler, Managing Director of Die Casting at Bühler, says, "We have a long history with Honda, and with the Carat 610, we are very pleased to provide the company with a solution to realise its mega casting ambitions."

"Our Carat series is the most successful solution on the market and is driving forward megacasting production across the world. Together with Honda, we have installed our megacasting solution in Japan. It was the first of its kind in the country." 

The Carat 610 was commissioned in March 2024 at Honda's site in Tochigi, Japan. This cell is being used for research and development (R&D). Honda is conducting controlled experiments under different casting conditions to ensure and improve the quality of their end products.

"Several parameters such as the casting temperature, the pressure, the casting speed, and the cooling rate can be varied in order to examine their effects on the properties of the parts," says Cornel Mendler.  

Image credit: Buhler