Finding
Pack assembly is local by necessity, and cell-to-pack and cell-to-body designs have moved pack engineering into the vehicle platform
A finished pack is heavy, high-voltage and classed as dangerous goods, so automakers assemble it near the vehicle line even when cells cross oceans. Tesla, BYD, GM, Hyundai, VW and BMW run their own pack lines, mostly inside the vehicle plant, which is why most plants below are vehicle plants with a pack line. Pack yield depends on weld quality, leak-tight cooling and end-of-line test throughput, not chemistry.
Pack architecture has changed faster than cell chemistry. Module-based packs gave way to cell-to-pack designs (CATL Qilin and Shenxing, BYD Blade), which remove module housings and raise volume use. Cell-to-body designs go further and make the pack the floor of the car: BYD CTB in the Seal, Tesla's structural 4680 pack, Leapmotor CTC. The tradeoff is repair: a structural pack is hard to open, service or reuse.
Storage is pulling pack lines away from cars. Ford is turning its Kentucky cell plants into LFP cell and container lines for grid storage, Ultium Spring Hill now feeds LG Energy Solution Vertech storage enclosures, and Tesla builds Megapack at its Brookshire, Texas plant. EU rules add a data layer: from February 18, 2027, EV and industrial batteries sold in the EU need a digital battery passport recording chemistry, origin, carbon footprint and recycled content. See BatteryPassportGuide.com.
US plants
U.S. battery pack factories
US plants with pack or module lines, standalone and inside vehicle plants.
| Plant | Location | Products | Chemistry | Status |
|---|---|---|---|---|
| Smyrna Tennessee Plant (AESC) | Smyrna, Tennessee | cells; packs | NMC | operational |
| Carlsbad Plant (American Lithium Energy) | Carlsbad, California | cells; packs | NMC | operational |
| Joplin Missouri Plant (EaglePicher) | Joplin, Missouri | cells; packs | NMC, lithium primary | operational |
| Factory ZERO (GM) | Detroit, Michigan | vehicles; packs | NMC | operational |
| Spring Hill EV Assembly (GM) | Spring Hill, Tennessee | vehicles; packs | NMC | operational |
| HMGMA Georgia (Metaplant) (Hyundai) | Ellabell, Georgia | vehicles; packs | NMC, LFP | operational |
| AutoLand Georgia (Kia) | West Point, Georgia | vehicles; packs | NMC | operational |
| Casa Grande Arizona Plant (AMP-1) (Lucid Motors) | Casa Grande, Arizona | vehicles; packs | NMC | operational |
| Tuscaloosa EV Assembly (Mercedes-Benz) | Vance, Alabama | vehicles; packs | NMC | operational |
| Clarksville Tennessee Plant (Microvast) | Clarksville, Tennessee | modules; packs | NMC, LFP | operational |
| Normal Illinois Plant (Rivian) | Normal, Illinois | vehicles; packs | NMC, LFP | operational |
| Jacksonville Plant (Saft America) | Jacksonville, Florida | cells; packs | NCA, NMC, lithium primary | operational |
| Gigafactory Fremont (Tesla) | Fremont, California | vehicles; packs | NCA | operational |
| Gigafactory Nevada (Tesla) | Sparks, Nevada | packs; drive units; LFP cells; Semi | NMC, LFP | operational |
| Gigafactory Texas cell and pack operations (Tesla) | Austin, Texas | cells; packs; cathode | NMC (high nickel) | operational |
| Gigafactory Texas vehicle assembly (Tesla) | Austin, Texas | vehicles; packs | operational | |
| Normal R2 expansion (Rivian) | Normal, Illinois | vehicles; packs | LFP, NMC | ramping |
| Toyota Battery North Carolina (Toyota) | Liberty, North Carolina | cells; packs | NMC, LFP | ramping |
| Bowling Green Kentucky Plant (AESC) | Bowling Green, Kentucky | cells; packs | NMC | under construction |
| Woodruff Battery Assembly (BMW) | Woodruff, South Carolina | packs | NMC | under construction |
| Auburn Hills Michigan Plant (Samsung SDI) | Auburn Hills, Michigan | modules; packs | NMC | under construction |
| Spartanburg EV Hub (BMW) | Greer, South Carolina | vehicles; packs | NMC | announced |
| East Liberty EV Assembly (Honda) | East Liberty, Ohio | vehicles; packs | NMC | announced |
| Ohio EV Hub (Marysville) (Honda) | Marysville, Ohio | vehicles; packs | NMC | announced |
| HMGMA Phase 2 (Hyundai) | Bryan County, Georgia | vehicles; packs | NMC, LFP | announced |
China
Chinese battery pack factories
BYD, Tesla Shanghai and Chinese automakers build packs beside their vehicle lines.
| Plant | Location | Products | Chemistry | Status |
|---|---|---|---|---|
| Changsha EV Assembly (BYD) | Changsha, China | vehicles; packs | LFP, NMC | operational |
| Changzhou EV Assembly (BYD) | Changzhou, China | vehicles; packs | LFP, NMC | operational |
| Hefei EV Assembly (BYD) | Hefei, China | vehicles; packs | LFP | operational |
| Shenzhen EV Assembly (HQ) (BYD) | Shenzhen, China | vehicles; packs | LFP, NMC | operational |
| Xi'an EV Assembly (BYD) | Xi'an, China | vehicles; packs | LFP | operational |
| Zhengzhou EV Assembly (BYD) | Zhengzhou, China | vehicles; packs | LFP | operational |
| Changsha Battery Plant (BYD (FinDreams Battery)) | Changsha, China | cells; packs | LFP, NMC | operational |
| Chongqing Battery Plant (BYD (FinDreams Battery)) | Chongqing, China | cells; packs | LFP, NMC | operational |
| Huizhou Battery Plant (BYD (FinDreams Battery)) | Huizhou, China | cells; packs | LFP, NMC | operational |
| Shenzhen HQ Battery Plant (BYD (FinDreams Battery)) | Shenzhen, China | cells; packs | LFP, NMC | operational |
| Xi'an Battery Plant (BYD (FinDreams Battery)) | Xi'an, China | cells; packs | LFP | operational |
| Zhengzhou Battery Plant (BYD (FinDreams Battery)) | Zhengzhou, China | cells; packs | LFP | operational |
| Wuhu EV Assembly (Chery) | Wuhu, China | vehicles; packs | NMC, LFP | operational |
| Luxeed EV Plant (AITO S7) (Chery (Luxeed)) | Wuhu, China | vehicles; packs | NMC | operational |
| Wuhan EV Hub (Voyah) (Dongfeng Motor) | Wuhan, China | vehicles; packs | NMC | operational |
| Changchun EV Hub (FAW Group) | Changchun, China | vehicles; packs | NMC | operational |
| Guangzhou Aion EV Plant (GAC Aion) | Guangzhou, China | vehicles; packs | NMC, LFP | operational |
| Guangzhou Toyota EV Plant (GAC-Toyota) | Guangzhou, China | vehicles; packs | NMC | operational |
| Hangzhou EV Hub (Geely) | Hangzhou, China | vehicles; packs | NMC, LFP | operational |
| Ningbo Zeekr EV Plant (Geely) | Ningbo, China | vehicles; packs | NMC | operational |
| Baoding EV Assembly (Great Wall Motor) | Baoding, China | vehicles; packs | NMC, LFP | operational |
| Taicang EV Plant (Great Wall Motor) | Taicang, China | vehicles; packs | LFP | operational |
| Wuhan Honda EV Plant (Honda-Dongfeng) | Wuhan, China | vehicles; packs | NMC | operational |
| Guangzhou Honda EV Plant (Honda-GAC) | Guangzhou, China | vehicles; packs | NMC | operational |
| Jinhua EV Plant (Leapmotor) | Jinhua, China | vehicles; packs | LFP | operational |
| Wuhan Nissan EV Plant (Nissan-Dongfeng) | Wuhan, China | vehicles; packs | NMC | operational |
| Anting EV Hub (SAIC) | Anting, China | vehicles; packs | NMC, LFP | operational |
| Wuhan EV Assembly (Ultium China) (SAIC-GM) | Wuhan, China | vehicles; packs | NMC | operational |
| Liuzhou EV Plant (SAIC-GM-Wuling) | Liuzhou, China | vehicles; packs | LFP | operational |
| Anting VW EV Plant (SAIC-VW) | Anting, China | vehicles; packs | NMC | operational |
| Chongqing AITO EV Plant (Seres (AITO)) | Chongqing, China | vehicles; packs | NMC, LFP | operational |
| Gigafactory Shanghai (Tesla) | Shanghai, China | vehicles; packs | LFP, NMC | operational |
| Beijing SU7 EV Plant (Xiaomi Auto) | Yizhuang, China | vehicles; packs | NMC | operational |
| Wuhan EV Assembly (BYD) | Wuhan, China | vehicles; packs | LFP, NMC | under construction |
Worldwide
Battery pack factories in the rest of the world
Europe, Japan, Korea, India, Southeast Asia and Latin America.
| Plant | Location | Products | Chemistry | Status |
|---|---|---|---|---|
| Sunderland Cell Plant (AESC) | Sunderland, United Kingdom | cells; packs | NMC | operational |
| Ingolstadt EV Hub (Audi) | Ingolstadt, Germany | vehicles; packs | NMC | operational |
| Dingolfing EV Hub (BMW) | Dingolfing, Germany | vehicles; packs | NMC | operational |
| Leipzig plant (BMW) | Leipzig, Germany | vehicles; packs | NMC | operational |
| Brazil Gigafactory (BYD) | Camacari, Brazil | vehicles; packs | LFP | operational |
| Thailand Gigafactory (BYD) | Rayong, Thailand | vehicles; packs | LFP, NMC | operational |
| Surrey BC Plant (EaglePicher) | Surrey, British Columbia | cells; packs | NMC, lithium primary | operational |
| Ulsan Genesis EV Plant (Genesis) | Ulsan, South Korea | vehicles; packs | NMC | operational |
| Suzuka EV Plant (Honda) | Suzuka, Japan | vehicles; packs | NMC | operational |
| Asan EV Plant (Hyundai) | Asan, South Korea | vehicles; packs | NMC | operational |
| Chennai EV Assembly (Hyundai) | Chennai, India | vehicles; packs | NMC | operational |
| Gwangju EV Plant (Hyundai) | Gwangju, South Korea | vehicles; packs | LFP | operational |
| Nosovice Plant (Hyundai) | Nosovice, Czech Republic | vehicles; packs | NMC | operational |
| Karawang EV + Cell Campus (Hyundai-LG Energy Solution) | Karawang, Indonesia | vehicles; packs | NMC, LFP | operational |
| Solihull EV Hub (Jaguar Land Rover) | Solihull, United Kingdom | vehicles; packs | NMC | operational |
| Halol EV Assembly (JSW MG Motor (SAIC)) | Halol, India | vehicles; packs | NMC, LFP | operational |
| Hwaseong EV Plant (EV6/EV9) (Kia) | Hwaseong, South Korea | vehicles; packs | NMC | operational |
| Sohari EV Plant (Kia) | Gwangmyeong, South Korea | vehicles; packs | LFP, NMC | operational |
| Pune EV Assembly (Mahindra Electric) | Pune, India | vehicles; packs | NMC | operational |
| Bremen Plant (EQE SUV) (Mercedes-Benz) | Bremen, Germany | vehicles; packs | NMC | operational |
| Sindelfingen EV Hub (EQS) (Mercedes-Benz) | Sindelfingen, Germany | vehicles; packs | NMC | operational |
| Okazaki EV Plant (Mitsubishi) | Okazaki, Japan | vehicles; packs | LFP | operational |
| Oppama EV Plant (Nissan) | Yokosuka, Japan | vehicles; packs | NMC, LFP | operational |
| Leipzig plant (Macan Electric) (Porsche) | Leipzig, Germany | vehicles; packs | NMC | operational |
| Douai ElectriCity Plant (Renault) | Douai, France | vehicles; packs | LFP, NMC | operational |
| Ellesmere Port EV Plant (Vauxhall) (Stellantis) | Ellesmere Port, United Kingdom | vehicles; packs | LFP | operational |
| Kenitra EV Plant (Morocco) (Stellantis) | Kenitra, Morocco | vehicles; packs | LFP | operational |
| Melfi EV Plant (Jeep/DS) (Stellantis) | Melfi, Italy | vehicles; packs | NMC | operational |
| Mirafiori EV Plant (500e/Maserati) (Stellantis) | Turin, Italy | vehicles; packs | NMC | operational |
| Poissy EV Plant (DS/Opel) (Stellantis) | Poissy, France | vehicles; packs | NMC | operational |
| Sanand EV Assembly (Tata Motors) | Sanand, India | vehicles; packs | NMC, LFP | operational |
| Gigafactory Berlin (Tesla) | Grunheide, Germany | vehicles; packs | NMC, LFP | operational |
| Motomachi EV Plant (Toyota) | Toyota City, Japan | vehicles; packs | NMC | operational |
| Emden EV Plant (Volkswagen) | Emden, Germany | vehicles; packs | NMC | operational |
| Zwickau EV Plant (Volkswagen) | Zwickau, Germany | vehicles; packs | NMC, LFP | operational |
| Ghent EV Plant (Volvo Cars) | Ghent, Belgium | vehicles; packs | NMC | operational |
| Debrecen plant (Neue Klasse) (BMW) | Debrecen, Hungary | vehicles; packs | ramping | |
| Munich Plant (Neue Klasse) (BMW) | Munich, Germany | vehicles; packs | NMC | ramping |
| Ulsan EV Hub (Hyundai) | Ulsan, South Korea | vehicles; packs | NMC, LFP | under construction |
| Tsutsumi EV Hub (Toyota) | Toyota City, Japan | vehicles; packs | NMC | under construction |
| Puebla EV Plant (Mexico) (Volkswagen) | Puebla, Mexico | vehicles; packs | NMC, LFP | under construction |
| Wolfsburg EV Hub (Volkswagen) | Wolfsburg, Germany | vehicles; packs | NMC, LFP | under construction |
| San Luis Potosi EV Plant (BMW) | San Luis Potosi, Mexico | vehicles; packs | NMC | announced |
Stopped
Cancelled, paused and closed pack lines
Plants whose pack or vehicle program stopped.
| Plant | Location | Status | What happened |
|---|---|---|---|
| Tongxiang EV Plant (Hozon Auto (NETA)) | Tongxiang, China | paused | Hozon Auto entered restructuring in 2025; production halted (unverified) |
| BlueOval City (Stanton TN) (BlueOval SK (Ford-SK On)) | Stanton, Tennessee | cancelled | Ford dropped the electric truck program here in 2025; plans gasoline trucks later in the decade (unverified) |
| Brussels EV Plant (e-tron) (Audi) | Brussels, Belgium | closed | Q8 e-tron production ended and the plant closed in February 2025 |
| Dearborn EV Assembly (Ford) | Dearborn, Michigan | closed | Battery-electric F-150 Lightning production ended in December 2025; Ford plans an extended-range Lightning with a gasoline generator |
| Chengdu Polestar EV Plant (Geely / Polestar) | Chengdu, China | closed | Built the Polestar 1 until 2021; current use unverified |
| Smyrna EV Assembly (Nissan) | Smyrna, Tennessee | closed | The third-generation Leaf is built in Tochigi, Japan; EV output at Smyrna ended (unverified) |
| Flins Renault Re-Factory (Renault) | Flins, France | closed | Vehicle assembly ended in 2024; the site is the Refactory (refurbishing and recycling) |
| Chattanooga EV Assembly (Volkswagen) | Chattanooga, Tennessee | closed | ID.4 production ended in 2026; the plant builds the Atlas |
Components
What goes into a pack besides cells
About a quarter of pack cost is housing, thermal, electrical and electronic hardware.
| Subsystem | Examples | Suppliers |
|---|---|---|
| Housing and structure | Extruded or cast aluminum trays, steel or composite lids | Constellium, Novelis, Hydro, Minth (China), Lingyun (China) |
| Thermal | Cold plates, thermal interface material, coolant manifolds | Dana, Modine, Valeo, Sanhua (China), Yinlun (China); Henkel, Parker for TIM |
| Electronics | BMS boards, cell monitoring chips, current sensors | TI, Analog Devices, NXP, Infineon; BYD Semiconductor, Sinowealth |
| HV safety | Contactors, fuses, pyrofuses, interlock loop | TE Connectivity, Eaton, Mersen, Littelfuse, Autoliv; Hongfa (China) |
Architecture
Module, cell-to-pack, cell-to-body
Each step removes structure and raises energy per liter, and each makes repair harder.
| Architecture | Examples | Gain | Cost |
|---|---|---|---|
| Module-based | Older Ultium, many legacy platforms | Serviceable, proven | Lowest volume use, heavier |
| Cell-to-pack (CTP) | CATL Qilin and Shenxing, BYD Blade, Tesla LFP packs | Fewer parts, higher energy per liter | Cells hard to replace |
| Cell-to-body or chassis (CTB, CTC) | BYD CTB (Seal), Tesla structural 4680 pack, Leapmotor CTC | Lower mass, stiffer body | Crash validation, near-zero repairability |
Sources
Sources and scope
- Scope
- Battery Pack Gigafactories
- Sources
- ElectronsX gigafactory dataset; EU Battery Regulation (2023/1542); company releases and trade press, 2025-2026
- Updated
- October 2026