Swiss technology company Bühler Group has delivered its first megacasting solutions to Honda as the Japanese automaker ramps up electric vehicle (EV) production in the United States. Honda has installed several Bühler Carat 610 die-casting machines, with one dedicated to research in Japan and others deployed at its Anna Engine Plant in Ohio.
Honda has been developing an EV production hub in Ohio since 2022, with assembly set to take place at its Marysville facility. Production will begin later this year with the Acura RSX SUV, followed by models based on the Honda 0 saloon and Honda 0 SUV prototypes revealed at CES 2025. A key component, the Intelligent Power Unit (IPU) housing, will be manufactured using Bühler’s equipment. The IPU casing, which also houses the battery, serves as a structural frame for Honda and Acura EVs.
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According to Bühler, megacasting simplifies manufacturing by replacing up to 100 individual components with a single die-cast part. Honda has installed six 6,000-tonne high-pressure die-casting machines at its Anna plant. “The battery case is much larger than anything Honda has die-cast before and is made in two halves, which are welded together at a later process,” Honda USA stated. The installation required structural modifications, including pilings extending 80 feet beneath the plant’s concrete floor to support the 31-foot-tall machines.
Honda began testing the process in Tochigi, Japan, in March 2024, adjusting parameters such as molding temperature, pressure, and cooling speed to optimize part quality. “In-house production of IPUs is a first for Honda,” a company representative said. “Bühler’s expertise and Carat 610 technology will ensure successful production.”
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Bühler’s Die Casting Managing Director Cornel Mendler said the company is proud to support Honda’s megacasting ambitions. “Our Carat series is the most successful solution on the market and is driving megacasting adoption globally. With Honda, we installed Japan’s first megacasting solution, and now we are bringing that expertise to the U.S.”