Swiss technology company Bühler Group has supplied Honda Motor Company Ltd. with their first megacasting solutions. The Japanese automobile manufacturer has invested in multiple Bühler Carat 610 die-casting machines to accelerate electric vehicle (EV) production across its network in North America and meet continued strong customer demand across the region. Honda is using one of the Carat 610 cells in Japan for research and development, and the others will be operated at the Anna Engine Plant, in Anna, Ohio, US.
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 the US supports its vision to make battery-electric and fuel-cell electric vehicles represent 100% 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. They will be manufactured at the Anna Engine Plant, then delivered to the EV Hub in Marysville where the battery modules will be installed.
“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 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.”
“We have installed our first megacasting machine in Honda 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. 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,” said Cornel Mendler, Managing Director Die Casting at Bühler.
“The use of various fully-automated peripheral devices, such as spray robots for applying release agents, removal robots for lifting the parts from the moulds, trimming presses for removing casting flashes and the cooling basin for regulating cooling processes, enables precise control of the entire casting process and helps to achieve 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 optimise our processes. The expertise and experience that we gain in Japan will be shared across our production network in North America to support our electrified future,” said a Honda spokesperson.
“The first Carat 610 cells have already been installed at Honda’s Anna Engine Plant and production is ramping up. This project is a global cooperation between our teams in Japan and the US. 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,” said Mendler.
