7 of America’s largest EV plants by factory size and production capacity

America’s electric vehicle industry is no longer confined to a handful of specialized factories. From California and Texas to Georgia and Tennessee, automakers are building or expanding massive manufacturing campuses designed to produce hundreds of thousands of electric vehicles each year. These facilities vary considerably. Some are dedicated EV plants, while others are flexible factories that manufacture electric, hybrid, and conventional vehicles on the same production lines. Ranking them is therefore not perfectly straightforward. Here are seven of the largest and most important EV manufacturing plants and campuses in the United States, based on a combination of physical scale and production capacity. Hyundai’s Metaplant America near Savannah is among the largest dedicated EV manufacturing facilities in the country. The massive complex covers roughly 7.5 million square feet and has been designed for an annual capacity of up to 500,000 vehicles across Hyundai, Kia, and Genesis brands. The highly automated facility is expected to become a major center for the group’s U.S. electrification strategy. Its scale also extends beyond vehicle assembly, with nearby battery production forming part of Hyundai’s broader manufacturing ecosystem in Georgia. 2. Tesla Fremont Factory, California Tesla’s Fremont Factory remains one of the most important EV production sites in the United States. The California facility was converted from a former joint venture automobile plant into Tesla’s primary early manufacturing hub and produces multiple models. Industry data compiled by the International Council on Clean Transportation lists Fremont with EV production capacity of approximately 515,000 vehicles annually. While Tesla’s newer factories may be more technologically advanced, Fremont remains one of the largest EV manufacturing operations in the country by output. 3. Ford BlueOval City, Tennessee Ford’s BlueOval City is less a single factory than an enormous EV manufacturing ecosystem. Located in West Tennessee, the nearly six-square-mile campus will include electric truck production, battery manufacturing, and a supplier park. Ford says the site will be among the largest automotive manufacturing facilities in U.S. history. The broader campus has been designed around a vertically integrated approach, bringing vehicle assembly and battery production together at one of the country’s largest automotive industrial sites. 4. Tesla Gigafactory Texas Tesla’s Gigafactory Texas near Austin is another giant of American EV manufacturing. The facility spans more than 10 million square feet and produces the Model Y and Cybertruck while also supporting battery and other advanced manufacturing operations. IEEE Spectrum reported that the factory has a production capacity of around 375,000 vehicles annually, making it one of Tesla’s most important global manufacturing hubs. 5. Lucid AMP-1, Arizona Lucid’s Advanced Manufacturing Plant, or AMP-1, in Casa Grande, Arizona, is one of the largest dedicated EV manufacturing sites built by a U.S. startup. The facility is being expanded in stages to support future vehicle production. ICCT data lists the broader AMP-1 manufacturing operation with potential capacity of up to 400,000 vehicles annually. The plant currently serves as the production center for Lucid’s Air sedan and Gravity SUV. 6. Rivian Normal Factory, Illinois Rivian’s Normal, Illinois, factory is a major EV production hub occupying the former Mitsubishi Motors manufacturing complex. The plant produces Rivian’s R1T pickup, R1S SUV, and commercial vans. According to ICCT data, the facility had EV production listed at around 48,000 vehicles, though Rivian has continued investing in expansion and production infrastructure. Its importance is likely to grow as Rivian prepares for the next generation of smaller and more affordable electric vehicles. 7. GM Factory ZERO, Michigan General Motors transformed its Detroit-Hamtramck Assembly Center into Factory ZERO, a flagship facility for the company’s EV strategy. GM has invested billions of dollars into the plant, which produces electric vehicles including the Chevrolet Silverado EV and GMC Hummer EV. ICCT data lists potential EV production of approximately 87,500 vehicles annually. While smaller than some of the newest mega-campuses, Factory ZERO represents one of the most significant conversions of a traditional American auto plant into an EV-focused manufacturing operation. America’s EV factory boom is still evolving The ranking of America’s largest EV plants could change rapidly. In fact, by the time you read this list it may have already been outdated. New facilities, expansions, and battery factories are continuing to reshape the industry, while some automakers are also adjusting production plans in response to changing EV demand. Ford’s BlueOval City and Hyundai’s Georgia Metaplant demonstrate how the industry is increasingly moving toward massive manufacturing ecosystems that combine vehicle assembly, batteries, and suppliers in a single region. Meanwhile, Tesla’s Fremont and Texas factories show that both established and newer plants will continue to play major roles in U.S. EV production. And increasingly, the biggest EV factory may no longer be defined simply by the number of cars rolling off a single assembly line, but by the size of the entire industrial ecosystem built around them. Get the latest in engineering, tech, space & science - delivered daily to your inbox.Kaif Shaikh is a journalist and writer passionate about turning complex information into clear, impactful stories. His writing covers technology, sustainability, geopolitics, and occasionally fiction. A graduate in Journalism and Mass Communication, his work has appeared in the Times of India and beyond. After a near-fatal experience, Kaif began seeing both stories and silences differently. Outside work, he juggles far too many projects and passions, but always makes time to read, reflect, and hold onto the thread of wonder.