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EV & battery gigafactoriescell manufacturing, cathode/anode materials, EV OEM plants
Lithium-ion cell gigafactories (LFP, NMC, emerging sodium-ion), upstream active materials (pCAM/CAM, graphite/silicon anodes), pack assembly and EV/e-2W OEM assembly plants. China dominates (~75-85% of cell capacity; Chinese automakers supplied 60% of global EV sales in 2025), while US/EU/India build localised supply under IRA/OBBBA 45X, EU Battery Regulation and India's ACC-PLI. Capital risk is acute: Northvolt's 2024-25 bankruptcy, US EV credit expiry (30-Sep-2025) and resulting write-downs/plant re-purposing, ramp/yield failures, metal price swings and policy whiplash.
Pack v1.0.0 · updated 5 Oct 2026 · 10 cited sources · 13 parameters · 10 swing factors.
At a glance
Pack defaults with their low–high range. Overruns are sector means as a share of the original budget or schedule. All parameters and sources
Sub-industries
Capex intensity ranges by configuration. The unit changes with the asset, so compare within a row, not across rows.
| Sub-industry | Capex intensity | Notes |
|---|---|---|
| Li-ion cell gigafactories (LFP/NMC/LMFP, sodium-ion)10-60 GWh/yr cell plants: CATL, BYD, LGES, Panasonic, Samsung SDI, SK On, Tesla, AESC; India: Ola (Krishnagiri), Agratas/Tata (Sanand), Reliance (Jamnagar), Amara Raja, Exide. | 40–130USD million per GWh/yr | estimate: China ~USD 40-60m/GWh; US/EU/India ~USD 80-130m/GWh (e.g., Agratas Sanand 20 GWh ~Rs 13,000 crore ~USD 70m/GWh at INR 95.8). |
| Cathode (pCAM/CAM), anode and electrolyte plantsUmicore, EcoPro, POSCO Future M, L&F, BASF; Epsilon (India anode/cathode), Himadri; graphite anode (Novonix, Syrah). | 15–60USD million per GWh-equivalent | estimate. |
| EV and e-2W/3W vehicle assembly plantsBody-in-white, paint, general assembly, battery pack lines; Tesla, BYD, Hyundai-Kia Metaplant, VW, Tata Motors PV (Sanand), M&M (Chakan), Ola/Ather/TVS e-2W plants; VinFast Tamil Nadu. | 300–10,000USD per unit of annual capacity | estimate: cars USD 4,000-10,000 per unit/yr (e.g., USD 1-2.5bn for 200-300k units); e-2W USD 300-800 per unit/yr. |
| Battery pack/module assemblyPack integration (BMS, thermal) by OEMs and suppliers (Tata AutoComp, Exicom, Log9). | 5–20USD million per GWh/yr | estimate. |
| Battery recycling and black-mass refiningRedwood, Li-Cycle (restructured), Umicore, Attero, Lohum, Gravita. | 50–250USD million per 10 kt/yr | estimate; economics depend on Ni/Co/Li prices and EU recycled-content rules. |
Value chain
Inputs
- lithium carbonate/hydroxide
- nickel, cobalt, manganese sulphates
- iron phosphate / LFP precursors
- graphite (natural/synthetic) and silicon
- copper and aluminium foils
- electrolyte (LiPF6) and separators
- dry rooms, coaters, calenders, formation/aging equipment
- low-carbon power and water
- automotive steel/aluminium, semiconductors (vehicle plants)
Process
- electrode slurry mixing and coating
- calendering and slitting
- cell assembly (stacking/winding), electrolyte filling
- formation and aging (largest energy use)
- module/pack integration
- vehicle body, paint and general assembly
- end-of-line testing and homologation
- recycling of scrap and end-of-life batteries
Outputs
- EV, ESS and e-2W cells
- battery packs
- BEVs/PHEVs, e-buses, e-trucks, e-2W/3W
- cathode/anode materials
- recycled black mass and metals
Parameters
13 parameters: 3 sourced, 10 informed estimates. The bar shows the low–high range with the default marked; estimates are labelled and never presented as observed data.
| Parameter | Default & range | Evidence | Source |
|---|---|---|---|
| Capex intensity(cell plant, ex-China) | 90 USD million per GWh/yrrange 40–130 | estimateas of 5 Oct 2026 | Informed estimate; no single source |
| Construction months(groundbreak to SOP; full ramp +12-24) | 30 monthsrange 18–48 | estimateas of 5 Oct 2026 | Informed estimate; no single source |
| Cost overrun mean | 25%range 0%–100% | estimateas of 5 Oct 2026 | greenfield Western gigafactories |
| Schedule overrun mean | 50%range 10%–200% | sourcedas of 5 Oct 2026 | en.wikipedia.org |
| Asset life (years)(equipment 8-12) | 15 yearsrange 8–25 | estimateas of 5 Oct 2026 | Informed estimate; no single source |
| WACC | 10%range 7%–14% | estimateas of 5 Oct 2026 | Informed estimate; no single source |
| Typical IRR | 12%range −10%–25% | estimateas of 5 Oct 2026 | CATL-class returns ~20%; new entrants frequently negative |
| Utilization | 65%range 20%–90% | estimateas of 5 Oct 2026 | Informed estimate; no single source |
| Opex % of revenue(materials ~65-75% of cell cost) | 82%range 70%–95% | estimateas of 5 Oct 2026 | Informed estimate; no single source |
| EBITDA margin | 12%range −20%–30% | estimateas of 5 Oct 2026 | CATL ~25%, Korean cell makers 5-15%, new entrants negative |
| KWh per EV | 60 kWh per BEV carrange 20–110 | estimateas of 5 Oct 2026 | Informed estimate; no single source |
| Global EV sales 2026 mn | 23 million carsrange 20–25 | sourcedas of 5 Oct 2026 | iea.org |
| US 45x cell credit (USD per kWh)(cells) | 35 USD/kWhrange 0–35 | sourcedas of 5 Oct 2026 | en.wikipedia.org |
What moves value
Sorted by expected cost (probability × cost impact). Impacts are typical values for the sector; each one is driven by the shared factors listed, which is how one shock reaches several projects at once.
Market signals
What moves the case
Key variables with their typical range and what they hit in the model.
| Variable | Typical range | Affects |
|---|---|---|
| Lithium hydroxide priceLFP ~0.55-0.6 kg LCE/kWh, NMC ~0.7 kg; +USD 10/kg ~ +USD 6-8/kWh cell cost; ~USD 15/kg in Oct-2026. | 8–80USD/kg | Opex, Revenue |
| NickelNMC811 ~0.6-0.7 kg Ni/kWh; FRED USD 16,632/t (Jul-2026), +11% y/y. | 14,000–30,000USD/t | Opex |
| AluminiumCathode foils, cans, enclosures, vehicle bodies. | 2,000–3,500USD/t | Opex, Capex |
| CopperAnode foil ~0.5-0.8 kg/kWh plus ~60-80 kg per EV. | 7,000–14,000USD/t | Opex |
| Battery manufacturing PPIUS price signal incl. tariffs. | 200–320index | Revenue |
| Cell/pack priceChinese LFP cells ~USD 50-60/kWh vs US/EU ~USD 90-120/kWh - estimate; drives competitiveness of localised plants. | 50–160USD/kWh | Revenue, Margin |
| EV share of new car sales2025: China ~55%, Europe 28%, US <10%; India cars ~4-5% (estimate); global 2026e 28%. | 2%–65% | Revenue, Utilization |
| Gigafactory utilisationGlobal cell capacity far exceeds demand outside top-tier players; <60% utilisation is loss-making for new entrants. | 20%–90% | Margin |
Show 4 more variables
| Variable | Typical range | Affects |
|---|---|---|
| Production scrap / yield lossNew Western plants (Northvolt) suffered scrap of 30%+ during ramp vs <5% at CATL - estimate. | 3%–40% | Opex, Schedule |
| Production incentive (45X / ACC-PLI)US 45X: USD 35/kWh cells + USD 10/kWh modules (FEOC limits under OBBBA); India ACC-PLI tied to 60% DVA. | 0–45USD/kWh | Revenue, Margin |
| US 10-year TreasuryGreenfield gigafactories rely on DOE/EIB loans and project debt. | 3–6percent | Financing |
| INR per USDIndian cell plants import equipment (Chinese/Korean) and most materials. | 80–100INR/USD | Capex, Opex |
Price feeds (14)
| Series | Source / id | Unit | Frequency |
|---|---|---|---|
| Lithium hydroxide CIF CJK futures | LTH=FYahoo | USD/kg | daily |
| Global price of Nickel | PNICKUSDMFRED | USD/t | monthly |
| Global price of Aluminum | PALUMUSDMFRED | USD/t | monthly |
| Global price of Copper | PCOPPUSDMFRED | USD/t | monthly |
| PPI: Battery manufacturing | PCU335911335911FRED | index | monthly |
| PPI: Storage batteries (ex lead-acid) | WPU11790105FRED | index | monthly |
| PPI: Automobile, light truck and utility vehicle manufacturing | PCU336110336110FRED | index | monthly |
| PPI: Motor vehicle electrical and electronic equipment | PCU336320336320FRED | index | monthly |
Show 6 more feeds
| Series | Source / id | Unit | Frequency |
|---|---|---|---|
| PPI: Steel mill products | WPU1017FRED | index | monthly |
| PPI: Industrial electric power | WPU0543FRED | index | monthly |
| US 10-year Treasury yield | DGS10FRED | percent | daily |
| INR per USD | DEXINUSFRED | INR/USD | daily |
| USD per EUR | DEXUSEUFRED | USD/EUR | daily |
| Global X Lithium & Battery Tech ETF | LITYahoo | USD | daily |
Listed tickers (28)
Market context only: these prices tend to react first when a driver moves. Named for context; no affiliation.
Operators · 17
- OLAELEC.NS Ola Electric (cell gigafactory + e-2W) NSE · IN
- ATHERENERG.NS Ather Energy NSE · IN
- TVSMOTOR.NS TVS Motor NSE · IN
- BAJAJ-AUTO.NS Bajaj Auto NSE · IN
- HYUNDAI.NS Hyundai Motor India NSE · IN
- EXIDEIND.NS Exide Industries (Exide Energy cells) NSE · IN
- ARE&M.NS Amara Raja Energy & Mobility NSE · IN
- RELIANCE.NS Reliance Industries (battery giga-complex) NSE · IN
- TSLA Tesla NASDAQ · US
- GM General Motors NYSE · US
- F Ford Motor NYSE · US
- RIVN Rivian NASDAQ · US
- VOW3.DE Volkswagen (PowerCo) XETRA · EU
- BMW.DE BMW XETRA · EU
- MBG.DE Mercedes-Benz (ACC shareholder) XETRA · EU
- STLAM.MI Stellantis (ACC shareholder) Borsa Italiana · EU
- 1211.HK BYD HKEX · APAC
Suppliers · 8
- ALB Albemarle NYSE · US
- SQM SQM NYSE · LATAM
- UMI.BR Umicore Euronext Brussels · EU
- 300750.SZ CATL SZSE · APAC
- 373220.KS LG Energy Solution KRX · APAC
- 006400.KS Samsung SDI KRX · APAC
- 096770.KS SK Innovation (SK On) KRX · APAC
- 6752.T Panasonic Holdings TSE · APAC
Consumers · 2
- TMPV.NS Tata Motors Passenger Vehicles (Tata.ev, JLR; Agratas parent group) NSE · IN
- M&M.NS Mahindra & Mahindra NSE · IN
Proxys · 1
- LIT Global X Lithium & Battery Tech ETF NYSE Arca · US
Trends and research findings
Trends
- EV growth shifts geographically2025-2030
2025: Europe EV share 28% (+30% sales), China ~55%, US just under 10% with sales falling after credits ended; 2026 global sales expected at 23m (28%).
- Chinese OEM dominance2025-2030
Chinese automakers supplied 60% of global EV sales in 2025; 70% of BEVs sold in China were cheaper than the average conventional car.
- US EV credit expiry and plant re-purposing2025-2028
New and used EV tax credits ended 30-Sep-2025; charging credits end 30-Jun-2026; cell plants pivot to ESS/LFP to retain 45X under FEOC rules.
- European gigafactory shake-out2024-2028
Northvolt filed Ch.11 (Nov-2024) and Swedish bankruptcy (Mar-2025); Chinese makers (CATL Hungary/Spain) fill the gap.
- Chinese overseas investment2020-2030
Chinese EV and battery makers announced ~USD 80bn of overseas manufacturing investment in five years (Indonesia, Thailand, Brazil, Mexico, Turkiye).
- Electric trucks and two-wheelers2025-2035
Electric truck sales more than doubled in 2025 to 9% of global truck sales; e-2W/3W growth strong in India and SE Asia.
Research findings
- Tesla capex (SEC)
Tesla purchases of PP&E fell to USD 8.53bn in 2025 from USD 11.34bn in 2024.
- EV fleet oil displacement
The global EV fleet avoided ~1.7 mb/d of oil consumption in 2025; EV fleet could grow >6x to ~510m by 2035 under current policies.
- Battery cost history
Prices for all Li-ion cell types fell ~99% between 1991 and 2024 in USD/kWh.
- US battery price inflation vs global deflation
US battery manufacturing PPI +26% and storage-battery PPI +32% since Jan-2020 (Aug-2026), reflecting tariffs and localisation costs.
- Metals exposure
Copper +125%, aluminium +78% and nickel +23% vs Jan-2020 (FRED, Jul-2026).
- Q1-2026 market dip
Global electric car sales of ~3.9m in Q1-2026 were 8% lower y/y on policy changes in China and the US, while Europe grew ~30%.
KPIs, regions and who builds
KPIs the pack tracks
Regional notes
| India | ACC-PLI (Rs 18,100 crore for 50 GWh) progress lagged with penalties for missed milestones (Ola, Reliance, Rajesh Exports); private non-PLI cell plants (Agratas, Amara Raja, Exide) ramping 2025-27; PM E-DRIVE (Rs 10,900 crore) and SPMEPCI (import duty concession for >=USD 500m investment) support EVs; China's 2025 rare-earth magnet curbs hit e-2W output; INR ~96/USD inflates imported equipment cost. |
|---|---|
| United States | OBBBA ended consumer EV credits (30-Sep-2025) but kept 45X with FEOC restrictions; automakers took large EV write-downs and redirected cell capacity to ESS/LFP (often licensing CATL technology); tariffs on Chinese EVs/batteries; DOE loans under review. |
| Europe | EV share 28% (2025) under CO2 standards; Battery Regulation (carbon footprint, recycled content, passports); Northvolt failure and ACC pauses; Chinese plants in Hungary/Spain; proposed Automotive Package would loosen 2035 target but EV share still >90% by 2035 per IEA. |
| Middle East | Saudi Arabia (Lucid, Ceer, battery plans) and Morocco (Chinese cathode/cell plants) emerging hubs. |
Who builds and operates
Named for context; no affiliation. These are public market participants drawn from the research behind the pack. They are not Capibud clients or partners.
Operators · 13
- Agratas (Tata Group) 20 GWh Sanand cell plant (~Rs 13,000 crore) and 40 GWh Somerset, UK gigafactory for Tata.ev/JLR.
- Ola Electric ACC-PLI 20 GWh allocation; Krishnagiri 4680 cell gigafactory started at ~5 GWh; e-2W market-share losses and losses weigh on funding.
- Reliance New Energy ACC-PLI 10 GWh + additional allocation; Jamnagar battery giga-complex (LFP, sodium-ion via Faradion).
- Amara Raja / Exide Energy Non-PLI Li-ion cell plants (Telangana 16 GWh; Bengaluru 12 GWh phased).
- Tata Motors PV / M&M / Hyundai / Maruti Suzuki Indian EV car OEMs; Maruti e-Vitara exports; SPMEPCI encourages global OEM local plants.
- TVS / Bajaj / Ather / Hero e-2W leaders; PM E-DRIVE incentives and rare-earth magnet supply shocks (2025).
- Tesla Gigafactories Texas/Nevada/Berlin/Shanghai; capex USD 8.5bn in 2025 (USD 11.3bn 2024); LFP cell lines for Megapack.
- General Motors / Ultium Cells (LGES) Ultium plants re-tooled toward LFP and ESS after 2025 EV demand reset.
- Ford / BlueOval SK BlueOval SK JV unwound (2025); Kentucky/Tennessee plants re-scoped; LFP plant in Michigan with CATL licence.
- Hyundai Motor Group Metaplant / Toyota NC / Panasonic Kansas Large Southeastern US EV/battery investments; immigration raid at Hyundai-LGES Georgia site (Sep-2025) delayed ramp.
- VW PowerCo / ACC (Stellantis-Mercedes-Total) / Verkor PowerCo Salzgitter/Valencia/St Thomas; ACC paused German/Italian plants; Verkor Dunkirk.
- Northvolt (assets acquired by Lyten) Largest Swedish industrial bankruptcy (Mar-2025) - cautionary case on ramp/yield.
- CATL / BYD / CALB / Gotion / EVE Chinese leaders expanding in Hungary (Debrecen), Spain (Stellantis-CATL Zaragoza), Indonesia, Morocco.
Suppliers · 11
- Wuxi Lead / Yinghe / Hirano / PNT Electrode coating, winding/stacking and formation equipment (mostly Chinese/Korean).
- Albemarle / SQM / Ganfeng / Tianqi / Pilbara Lithium chemicals.
- Umicore / EcoPro / POSCO Future M / L&F / BASF Cathode materials; Umicore scaled back battery materials capex 2024-25.
- Epsilon Advanced Materials / Himadri / Altmin / Hindalco Indian anode, LFP cathode, aluminium foil suppliers.
- Asahi Kasei / SEMCORP / Toray Separators.
- Durr / ABB / Siemens / Bosch Rexroth Automation, dry-room HVAC, paint shops for vehicle plants.
- Exyte / Munters Dry-room and cleanroom systems.
- L&T / Tata Projects / Shapoorji / Kiewit / Walbridge Gigafactory and auto-plant EPC.
- Redwood Materials / Li-Cycle / Attero / Lohum Recycling and closed-loop materials.
- Sona Comstar / Uno Minda / Tata AutoComp EV traction motors, BMS and packs; rare-earth magnet exposure.
- Siemens Digital Industries / Dassault / Rockwell MES, digital twin and quality analytics for ramp/yield.
Customers · 5
- Passenger EV buyers Global EV sales 2026e 23m (28% share); Europe ~1 in 3 cars.
- Two- and three-wheeler riders India e-2W sales grew >30% y/y in Q1-2026; SE Asia doubled.
- Commercial fleets (buses, trucks, last-mile) Electric trucks 9% of global truck sales 2025; India PM e-Bus Sewa.
- Stationary storage (BESS) integrators Fastest-growing outlet for LFP cells; US EV lines converting to ESS.
- Automakers buying cells (offtake) Long-term supply agreements set utilisation of independent cell makers.
Project template
Work breakdown
Share of total duration per step; steps overlap where predecessors allow, as the bars show. O / ML / P are optimistic, most-likely and pessimistic multipliers on each step's duration; the hatched tail is the pessimistic case.
| ID | Step & timing | Share | O / ML / P |
|---|---|---|---|
| A100 | Offtake agreements, technology/licensing partner and business caseDevelop · factors: Policy, Interest rates, Oil | 15% | 0.9 / 1 / 1.6 |
| A110 | Incentive approvals (45X/DOE LPO, ACC-PLI, state packages) and financingDevelop · factors: Policy, Interest rates | 15% | 0.85 / 1 / 1.8 |
| A120 | Land, environmental clearance, power and water connectionsDevelop · factors: Policy, Grid queue | 20% | 0.9 / 1 / 1.6 |
| B100 | Process and facility design (dry rooms, formation, HVAC, solvent recovery)Engineer · EPC · factors: Labour | 15% | 0.9 / 1 / 1.4 |
| C100 | Process equipment orders (mixing, coating, assembly, formation)Procure · OEM · factors: Electrical equipment, Policy | 35% | 0.9 / 1 / 1.5 |
| C110 | Facility long-lead: substations, chillers, dry-room AHUs, NMP recoveryProcure · OEM · factors: Electrical equipment, Steel, Copper | 30% | 0.9 / 1 / 1.5 |
| C120 | Raw-material supply contracts (Li, CAM, anode, electrolyte, foils)Procure · factors: Policy, Aluminium, Copper, Electrical equipment | 20% | 0.9 / 1 / 1.6 |
| D100 | Civil works and building shellConstruct · EPC · factors: Construction materials, Steel, Labour | 30% | 0.9 / 1 / 1.4 |
| D110 | MEP, dry rooms and utilities installationConstruct · EPC · factors: Labour, Copper, Electrical equipment | 30% | 0.9 / 1 / 1.5 |
| D120 | Equipment installation and line integrationConstruct · OEM · factors: Labour, Electrical equipment | 20% | 0.9 / 1 / 1.6 |
| E100 | Pilot production, cell validation and customer (OEM) qualificationCommission · factors: Labour, Electrical equipment | 20% | 0.9 / 1 / 2 |
| E110 | SOP and volume ramp to nameplateCommission · factors: Labour, Policy, Oil | 25% | 0.9 / 1 / 2.2 |
Cost breakdown
Share of capex by line, with the commodity exposure of each line (the share of that line that moves with the commodity).
Financial template
Revenue model
Cell makers sell cells/packs under multi-year OEM or ESS offtake agreements with metal-price pass-through plus production incentives (45X USD 35/kWh cells, India ACC-PLI); OEM plants earn vehicle margins dependent on volume and battery cost; materials makers earn processing fees over metal indices.
Margin driver
Gigafactory utilisation
Ramp-up
3 years to steady state
How Capibud uses this pack
A pack is a starting position, not a forecast. When a EV & battery gigafactories decision opens in Capibud, pack v1.0.0 is copied in and pinned to that decision. The 13 parameters, 10 swing factors and templates the committee saw stay attached to the decision record, even after the pack is next refreshed.
Parameter ranges and WBS durations seed the P50, P80 and P90 for capex, schedule and value. Your own estimates, vendor quotes and actuals replace pack defaults line by line, and the record shows which numbers are still defaults.
Each swing factor is wired to shared factors; here the heaviest are policy, electrical equipment, labour and interest rates. A move in one factor hits every exposed project in the same scenario, which is how the capital committee sees concentration across a book rather than project by project.
The 14 price feeds and 28 listed tickers feed the brain, which watches for drivers moving outside their pack range and drafts the change for a person to review.
Shared factors behind this pack's swing factors
- Policy
- Electrical equipment
- Labour
- Interest rates
- Oil
- Aluminium
- Copper
Capex tied to a shared factor
- Electrical equipment42.4%
- Policy17.1%
- Labour14.5%
- Steel8.9%
- Construction materials6.5%
- Copper4.9%
- Interest rates3%
Sources
Every link opens the original source in a new tab. Values marked as estimates are informed estimates by the Capibud research team.
- iea.orghttps://www.iea.org/reports/global-ev-outlook-2026/executive-summary
- iea.orghttps://www.iea.org/reports/world-energy-investment-2025/executive-summary
- en.wikipedia.orghttps://en.wikipedia.org/wiki/Northvolt
- en.wikipedia.orghttps://en.wikipedia.org/wiki/One_Big_Beautiful_Bill_Act
- en.wikipedia.orghttps://en.wikipedia.org/wiki/Inflation_Reduction_Act
- en.wikipedia.orghttps://en.wikipedia.org/wiki/Gigafactory
- en.wikipedia.orghttps://en.wikipedia.org/wiki/Lithium-ion_battery
- data.sec.govhttps://data.sec.gov/api/xbrl/companyconcept/CIK0001318605/us-gaap/PaymentsToAcquirePropertyPlantAndEquipment.json
- fred.stlouisfed.orghttps://fred.stlouisfed.org/series/PCU335911335911
- fred.stlouisfed.orghttps://fred.stlouisfed.org/series/PNICKUSDM
Bring us one real decision in EV & battery gigafactories.
We start it from the EV & battery gigafactories pack v1.0.0: 13 parameters, 10 swing factors and the 12-step project template, pinned to your decision.