Plant Expansions Drive U.S. Automotive Kickoffs

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Written by Danny Levin, Deputy Editor for IIR News Intelligence (Sugar Land, Texas)

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Summary

Industrial Info Resources is tracking $9.7 billion worth of U.S. automotive projects that are planned to begin in the fourth quarter, most of which are attributed to plant expansions, compared with $6.2 billion in investment year-over-year.

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Plant Expansions Galore

According to Industrial Info Resources data, there are 34 U.S. automotive projects worth $9.7 billion that are planned to begin construction in the fourth quarter, with about 75% of the investment attributed to plant expansions. The spending compares with $6.2 billion in investment year-over-year and $9 billion in planned construction starts in first-quarter 2027.

It is important to note that not all of these projects will move forward as planned, as the number of actual kickoffs for each quarter is typically less than planned kickoffs.

David Pickering, Industrial Info Resources' senior vice president of research for the Industrial Manufacturing segment, notes factors driving the project activity include reshoring production to the U.S., especially amid the current trade war with Canada, and a shift to hybrid vehicle production.

Toyota is investing $3.6 billion to expand its manufacturing campus in San Antonio, Texas, which is designed to add an assembly line in order to onshore Tacoma production from Mexico. The onshoring effort comes as the automotive industry faces uncertainty around the United States-Mexico-Canada Agreement (USMCA) trade agreement and ongoing U.S. tariffs. The Industrial Info Resources Global Market Intelligence (GMI) Industrial Manufacturing Plant and Project databases offer a detailed plant profile and project report. For more information, readers can view the July 10, 2026, article - Toyota: $3.6 Billion to Shift Some Automotive Production to U.S. from Mexico.

Toyota is investing in two other expansions that could begin construction by the end of the year: a new machining line at its Georgetown Vehicle Assembly & Engines plant in Kentucky would support up to 700,000 units/year of four-cylinder hybrid-compatible engines, while a new vehicle assembly line at its Princeton Truck & SUV Assembly plant in Indiana will support increased and expanded production of the Grand Highlander sport utility vehicle (SUV). Readers can view more information on the Georgetown and Princeton projects.

Another project from a major automaker is General Motors' planned $157 million expansion of its Wentzville Assembly plant in Missouri, which produces trucks and vans. The project entails paint and modernization work, including a new 28,000-square-foot building and new paint processing equipment. View the project report here.

IIR offers a full list of automotive projects planned to kick off in the fourth quarter.

First-Quarter 2027 Starts

Two major plant expansions from Ford in Kentucky account for one-third of the planned investment for automotive kickoffs in the first quarter of 2027. This includes a recently announced $1 billion construction of a new paint shop at its Louisville Kentucky Truck Assembly Plant (KTP). The automaker on September 10 said groundbreaking is expected by late this year. Readers can access the detailed project report.

The announcement came just two days after U.S. Secretary of Transportation Sean Duffy, in a letter to Ford Chief Executive Officer Jim Farley, expressed "profound concern" over the automaker's ties to Chinese companies "as it pertains to American national automotive manufacturing integrity, supply chain exposure, and reliance on technologies of foreign adversaries." This includes its decision to use licensed technology from battery manufacturer Contemporary Amperex Technology Company, Limited at Ford's BlueOval Battery Park near Marshall, Michigan.

In a statement in response, Ford called the letter a "wrongheaded attempt to capture headlines."

The company noted its place as the United States' top-producing automaker and said it employs more hourly workers in the country than any other automaker.

This builds on a $2 billion expansion planned for its Louisville Light Assembly Plant, which will add a new assembly line for Ford's new, all-electric Ford Fathom mid-size pickup truck. Readers can view more information on the project.

"These investments demonstrate our confidence in Kentucky's workforce, our commitment to American manufacturing, and our belief that the future of mobility and energy will be built right here in the United States," said Farley in a press release.

Industrial Info Resources offers a full list of reports for projects that could kick off in the first quarter of 2027.

IIR also offers a full list of detailed reports for projects mentioned in this article, and a full list of related plant profiles.

Key Takeaways

• Plant expansions drive near-term U.S. automotive kickoffs.
• $9.7 billion: Total investment value of U.S. automotive projects that are planned to begin in the fourth quarter.
• Another $9 billion worth of projects could kick off in fourth-quarter 2027.

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About Industrial Info Resources
Industrial Info Resources (IIR) is the leading provider of industrial market intelligence. Since 1983, IIR has provided comprehensive research, news and analysis on the industrial process, manufacturing and energy related industries. IIR's Global Market Intelligence (GMI) helps companies identify and pursue trends across multiple markets with access to real, qualified and validated plant and project opportunities. Across the world, Industrial Info Resources is tracking over 250,000 current and future projects worth $30.2 trillion (USD).