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2/10/2025
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Report
Bühler supplies megacasting solutions for Honda’s production
Honda Motor Company Ltd. has partnered with Bühler Group to integrate megacasting technology into its production network. The company has acquired multiple Bühler Carat 610 die-casting machines to support the growth of its electric vehicle (EV) business in North America. While one machine is being used for research and development (R&D) in Japan, the others will be installed at the Anna Engine Plant in Ohio, USA.
Megacasting for Honda’s EV hub
Honda is strengthening its EV production capabilities in North America to meet increasing demand. The company is establishing an EV hub in Marysville, Ohio, where production of battery-electric and fuel-cell vehicles will begin this year. This expansion aligns with Honda’s goal of making EVs and fuel-cell electric vehicles 100% of its vehicle sales by 2040.
As part of this initiative, Honda is utilizing Bühler’s Carat 610 megacasting machines to produce the cases for its Intelligent Power Units (IPUs). These cases will house the battery module and serve as the main frame structure for the floor of Honda and Acura EVs. Manufacturing will take place at the Anna Engine Plant before final assembly at the Marysville EV Hub.
Establishing expertise through R&D
“The IPU case is much larger than anything Honda has die cast before. It will be die-cast in two pieces and welded together,” says a Honda representative. “In-house production of IPUs is a first 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.”Bühler has been a long-term partner of Honda and is supporting the company’s transition into megacasting. “We have a long history with Honda, and with the Carat 610, we are very pleased to provide the company with a solution to realize their megacasting ambitions,” says Cornel Mendler, Managing Director Die Casting at Bühler. “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 machine in Tochigi, Japan, was commissioned in March 2024 for R&D purposes. Honda is conducting controlled experiments to refine casting conditions and enhance product quality. “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,” explains Cornel Mendler.
This research process is further supported by automated peripheral devices, such as spray robots, removal robots, trimming presses, and cooling basins, which ensure precise process control and reproducible results. “The R&D cell makes it possible to test process innovations and newly developed parts quickly and efficiently. This rigorous testing allows us to optimize our processes,” says a Honda representative. “The expertise and experience that we gain in Japan will be shared across our production network in North America to support our electrified future.”
Cornel MendlerScaling production in North America
The first Carat 610 cells have already been installed at Honda’s Anna Engine Plant, with production now ramping up. “This project is a global cooperation between our teams in Japan and the US,” says Cornel Mendler. “Thanks to our worldwide setup, we are able to work closely with our customers and supply them with the technologies and solutions they need for success in the changing automotive landscape.”A proven solution for the future of manufacturing
Bühler has been a leader in die casting for nearly a century, and its Carat series is at the forefront of the megacasting trend in modern automotive manufacturing. The two-platen technology, with locking forces ranging from 10,500 to 92,000 kilonewtons (kN), is specifically designed for large and complex structural components.By reducing the number of parts in vehicle manufacturing, megacasting simplifies production, improves integration, and minimizes transportation needs. With over 900 Carat machines in operation worldwide, Bühler continues to drive innovation in die casting, supporting automakers in their transition toward more efficient and sustainable manufacturing processes.
