Top 10 BESS Reshoring Projects: $13.9 B from Toyota, 49.5 GWh from Next Star, and 8 Other Deals (2024-2026)

North America is executing a monumental shift in the electric vehicle (EV) supply chain, with automakers and battery manufacturers investing tens of billions to reshore production from Asia. This strategic pivot is driven by a desire for supply chain security, geopolitical stability, and government incentives. The data reveals a concentrated push to build a self-reliant battery manufacturing ecosystem, with investments of over $40 billion across the top projects alone. The dominant theme for 2025 is the transition from construction to commercial operation, as foundational projects like Toyota’s North Carolina plant and Panasonic’s Kansas facility begin mass production, marking the first tangible returns on these massive capital outlays.

Top 10 EV Supply Chain Reshoring Projects in North America (2024–2026)

The following projects represent the largest and most strategically significant investments in localizing the EV supply chain across the U.S., Canada, and Mexico. They are ranked by investment scale and their potential impact on regional battery and component manufacturing capacity.

1. Toyota Battery Manufacturing North Carolina (TBMNC)

• Companies: Toyota
• Location: Liberty, North Carolina
• Investment: $13.9 billion
• Capacity: 30 GWh annually (initial phase)
• Project Details: As Toyota’s first global battery plant, this facility is a landmark investment by a legacy automaker to onshore its battery supply for both hybrid and fully electric vehicles.
• Status: Production commenced in 2025.
• Source: Toyota NC Battery Factory Launches Despite Headwinds

2. Hyundai Motor Group Metaplant America

• Companies: Hyundai Motor Group
• Location: Bryan County, Georgia
• Investment: $5.54 billion
• Capacity: Not specified
• Project Details: This integrated EV and battery manufacturing “Metaplant” is Hyundai’s first dedicated facility of its kind in the U.S., localizing its entire production process.
• Status: Under construction.
• Source: Hey Big Spenders! Car Manufacturers Are Investing …

3. Next Star Energy Gigafactory (Stellantis & LGES JV)

• Companies: Stellantis, LG Energy Solution (LGES)
• Location: Windsor, Ontario, Canada
• Investment: $5 billion (CAD $6.7 billion)
• Capacity: 49.5 GWh annually
• Project Details: In February 2026, LGES announced it would acquire full ownership of this joint venture, making it a cornerstone of Canada’s EV ecosystem and a key supplier for Stellantis’s North American EVs.
• Status: Under construction.
• Source: LG Energy Solution to Acquire Full Ownership of Next Star …

4. Tesla & LG Energy Solution Michigan Plant

• Companies: Tesla, LG Energy Solution
• Location: Michigan, USA
• Investment: $4.3 billion
• Capacity: 50 GWh annually
• Project Details: Announced in March 2026, this JV will create one of the largest battery plants in the U.S. to bolster Tesla’s supply and expand LGES’s North American footprint, with production planned for 2027.
• Status: Announced, pre-construction.
• Source: Tesla and LG Energy to Build $4.3 Billion Battery Plant in …

5. GM & Samsung SDI Indiana Plant

• Companies: General Motors, Samsung SDI
• Location: New Carlisle, Indiana
• Investment: $3.5 billion
• Capacity: 30 GWh annually
• Project Details: This 2025 joint venture diversifies GM’s battery sourcing beyond its Ultium Cells partnership. The plant will produce high-nickel prismatic and cylindrical cells for improved performance.
• Status: Under construction.
• Source: Tag: battery cell and gigafactories

6. Ford Blue Oval Battery Park Michigan

• Companies: Ford Motor Company (with technology from CATL)
• Location: Marshall, Michigan
• Investment: $3 billion (revised)
• Capacity: 20 GWh annually (revised)
• Project Details: This facility is central to Ford’s strategy to onshore Lithium Iron Phosphate (LFP) battery production to reduce EV costs. As of June 2025, the plant was 60% complete, with production slated for 2026.
• Status: Under construction.
• Source: Ford to ‘stick behind’ Marshall plant amid threat to battery …

7. Panasonic Energy Kansas Plant

• Companies: Panasonic Energy
• Location: De Soto, Kansas
• Investment: Part of a multi-billion dollar expansion
• Capacity: 32 GWh annually
• Project Details: One of North America’s largest battery factories, this plant began mass production of 2170 cylindrical cells in July 2025, serving as a critical supplier for Tesla and other automakers.
• Status: Operational.
• Source: Opens One of North America’s Largest EV Battery Factories

8. Gotion High-Tech U.S. Plants

• Companies: Gotion High-Tech
• Location: Manteno, Illinois & Mecosta County, Michigan
• Investment: $4.36 billion (combined)
• Capacity: Michigan plant: 150, 000 tons of cathode and 50, 000 tons of anode material annually.
• Project Details: Gotion is establishing a vertically integrated U.S. supply chain, with battery component manufacturing in Michigan and pack assembly in Illinois.
• Status: Under construction.
• Source: The Booming Future of Solar and Battery Storage in North …

9. Minth Group U.S. Manufacturing Campus

• Companies: Minth Group
• Location: Not specified
• Investment: ~$430 million

– Capacity: N/A (component manufacturing)

• Project Details: Announced in June 2026, this investment from a major automotive component supplier signals the reshoring trend is broadening to include parts beyond battery cells.
• Status: Announced.
• Source: Automotive Industry Update

10. Scout Motors Supplier Park

• Companies: Scout Motors (Volkswagen Group)
• Location: Blythewood, South Carolina
• Investment: $300 million
• Capacity: N/A (supplier park)
• Project Details: Announced in December 2025, this park will co-locate key suppliers next to Scout’s assembly plant to shorten supply lines and improve manufacturing efficiency for its upcoming EVs.
• Status: Announced.
• Source: US Manufacturers Make Big Plans in 2025

Table: Top 10 North American EV Supply Chain Reshoring Projects (2024-2026)

Vertical Integration: Automakers Build End-to-End EV Supply Chains

A primary pattern emerging from these investments is the auto industry’s push for vertical integration. Automakers are no longer content to simply purchase batteries from third-party suppliers; they are now investing billions to control the entire value chain, from raw material processing to final pack assembly. This strategy is designed to mitigate supply disruptions, reduce costs, and gain a competitive edge in battery technology and performance.

From Cells to Cars: Hyundai’s Metaplant Model

Hyundai’s $5.54 billion “Metaplant” in Georgia exemplifies this trend. The facility is not just a battery factory but a fully integrated campus where both EVs and their batteries are manufactured side-by-side. This co-location drastically reduces logistics costs and complexities, enabling a more agile and efficient production system. Similarly, Toyota’s $13.9 billion investment in North Carolina gives the legacy giant unprecedented control over its battery supply, a critical move as it accelerates its transition to electric and hybrid models.

Beyond Batteries: Component and Supplier Parks

The reshoring effort extends beyond battery cells. Investments from companies like Scout Motors and Minth Group show that the entire ecosystem of EV components is being localized. Scout’s $300 million supplier park in South Carolina is designed to co-locate key suppliers directly at its assembly plant, mirroring the integrated model of larger automakers. This move, along with Minth Group’s $430 million campus for general automotive parts, indicates a broader industrial strategy to shorten supply lines for everything from chassis components to interior electronics, which also includes securing the Rare Earth Supply Chain 2026, $1.7 B US Funding, MP Materials.

US “Battery Belt” Versus the Midwest: A $40 B Geographic Split

The geographic distribution of these projects reveals two major hubs of EV manufacturing in North America. The U.S. Southeast is rapidly emerging as the “Battery Belt, ” attracting massive greenfield investments, while the traditional automotive heartland in the Midwest and Canada is seeing legacy sites retooled and expanded to accommodate EV production.

The Southeast’s Rise: Georgia and the Carolinas

The U.S. Southeast has become a magnet for investment, with Georgia, North Carolina, and South Carolina securing flagship projects. Hyundai’s Georgia Metaplant, Toyota’s North Carolina battery factory, and Scout Motors’ South Carolina assembly plant collectively represent over $20 billion in capital. This region offers lower labor costs, significant state-level incentives, and favorable logistics, making it an ideal location for building the next generation of automotive manufacturing from the ground up.

Midwest and Canada: Leveraging Legacy Infrastructure

The Great Lakes region is leveraging its deep-rooted automotive history to pivot to EV production. Michigan is a prime example, attracting a diverse range of projects including Ford’s LFP plant, Gotion’s component facilities, and the newly announced $4.3 billion Tesla-LGES joint venture. Nearby, GM’s $3.5 billion partnership with Samsung SDI in Indiana and Stellantis’s $5 billion gigafactory in Ontario demonstrate that legacy automakers are heavily investing in retooling their existing industrial footprint for an electric future.

Ford’s LFP Bet: A $3 B Move to Diversify Battery Chemistry

These investments are not just about adding capacity; they also reflect strategic decisions about which battery technologies will power the next generation of EVs. Automakers are diversifying their portfolios beyond high-nickel NCM (Nickel Cobalt Manganese) chemistries to include different technologies like LFP (Lithium Iron Phosphate), which offers cost and safety advantages.

Ford’s Marshall Plant and CATL Technology

Ford’s $3 billion Blue Oval Battery Park in Michigan is a clear strategic bet on LFP technology. By licensing technology from Chinese battery giant CATL, Ford aims to bring lower-cost battery production to North America, which is critical for producing more affordable EVs. Despite scaling back the plant’s initial capacity from 35 GWh to 20 GWh amid market adjustments, the company’s commitment to the project, confirmed as 60% complete in June 2025, underscores the long-term importance of LFP in its portfolio.

GM’s Multi-Partner Approach for Performance

In contrast, General Motors is pursuing a multi-partner, multi-chemistry strategy to secure its battery supply. While its primary partnership is with LGES through the Ultium Cells JVs, the new $3.5 billion plant with Samsung SDI in Indiana will produce high-nickel prismatic and cylindrical cells. This move diversifies GM’s suppliers and gives it access to different cell formats and chemistries, allowing it to optimize for both high-performance and mass-market vehicles.

North America’s EV Supply Chain Investment Hits $250B, Driven by Policy
North American investment in the Battery and EV supply chain has surged, reaching approximately $250 billion by early 2024. This cumulative investment, heavily driven by the Inflation Reduction Act (IRA) and Bipartisan Infrastructure Law (BIL), shows a clear trend towards localizing EV manufacturing, with cell production and EV assembly leading the capital allocation.

Policy-Driven Investment Bolsters Resilient North American EV Supply Chain
The rapid accumulation of over $250B in domestic investment signifies a robust, policy-backed drive to establish a resilient North American EV supply chain. This reduces geopolitical risks, enhances energy security, and fosters high-tech job growth, particularly in critical areas like battery cell manufacturing and advanced materials (CAM, AAM), which are pivotal for long-term competitiveness.

US Manufacturing Capital Investment Surged Post-COVID, Now Stabilizing
US manufacturing capital spending nearly tripled from $75,456M in 2020 to a peak of $235,608M in 2024. Despite a -5% dip to $223,892M projected for 2025, the overall trend reflects aggressive post-COVID domestic investment, largely driven by supply chain resilience efforts.

(Source: 2026 Reshoring Index | Kearney)

2026 EV Battery Supply: Navigating Oversupply and the US-China Split

The critical strategic action for 2026 is managing the dual risks of regional battery oversupply and the persistent Clean Energy Manufacturing 2026: The US-China Supply Chain Split. If the massive wave of new North American capacity comes online as scheduled, projections indicate that manufacturing capability could surpass regional demand. In this scenario, watch for intense price competition, project delays, and potential market consolidation. This could trigger several downstream effects:

• The decision to scale back projects, such as Ford’s Michigan plant reducing its planned capacity to 20 GWh, is an early signal that companies are actively hedging against a potential supply glut and softening demand forecasts.
• Consolidation among battery manufacturers may accelerate, as seen with LG Energy Solution’s February 2026 move to acquire full ownership of the Next Star Energy JV. Larger, more capitalized players are likely to absorb smaller competitors or buy out JV partners to secure market share and streamline operations.
• Major players may make aggressive late-stage moves to solidify their dominance. The announcement of the huge 50 GWh Tesla-LGES plant in March 2026 suggests an effort by market leaders to leverage economies of scale and squeeze out less efficient producers, potentially creating an oversupply scenario for others.

The questions your competitors are already asking

This report covers one angle of the major EV battery factory investments in North America. The questions that matter most depend on your work.

• EV sales forecasts vs battery factory capacity US
• lithium supply contracts for US battery plants
• US government battery factory incentive changes
• new battery component supplier investments US

This report does not answer these. Enki Brief Pro does.

Your question, your angle, your framework. SWOT, PESTL, scenario modelling. The same niche depth, built around the decision your work actually depends on.

Run your first brief in Enki Brief Pro