Dura Opens High-Tech Factory in Muscle Shoals for EV Battery Enclosures

From Alabama Department of Commerce:

MUSCLE SHOALS, Alabama — Governor Kay Ivey joined officials with Dura Automotive Systems today to celebrate the formal unveiling of the company's new state-of-the-art manufacturing facility in Muscle Shoals, which will produce electric vehicle battery enclosures. 

The 200,000-square-foot facility is expected to employ more than 270 full-time workers at peak production, with an estimated investment of $75 million.

It will supply lightweight aluminum EV battery enclosures to the Mercedes-Benz electric battery assembly plant in Bibb County.

"It has been 25 years since Mercedes-Benz helped launch our automotive industry, and in that time, Alabama has grown to become a national leader in vehicle exports," Governor Ivey said.

"I'm incredibly excited to welcome Dura Automotive Systems to Alabama's booming automotive industry, and I look forward to seeing this company continue to grow in our great state," she added.

The Alabama facility is Dura's most recent addition to a growing family of worldwide sites and home to the company's first lightweight structures investment in North America. The premier site is designed to support the rapid production of luxury electric vehicles planned throughout the next decade.

The high-tech manufacturing processes at Dura's Alabama facility will utilize advanced robotics and proprietary forming and joining technologies to create lightweight structures used for EV battery systems.

"This milestone event celebrates our continued partnership with customers to accelerate the transition to electrified, high-performance vehicles," Dura CEO Carl Beckwith said. "On behalf of Dura and our investors, I extend appreciation to our employees, Mercedes-Benz, and the many individuals in the government and supply base that worked above and beyond to make this vision a reality.

"Your accomplishment adds yet another steppingstone along the path toward a zero-emission future," he added.

ADVANCED PROCESSES

The Muscle Shoals factory boasts significant safety, efficiency, and environmentally clean processes. These include:

• A symphony of more than 60 robots, trained and conducted by technical experts, is deployed throughout manufacturing.
• More than 500 light curtains, lasers, and proximity switches are active to ensure safety for personnel throughout the site.
• Extensive LED lighting throughout the building is controlled through motion activation to minimize energy consumption.
• Advanced water treatment systems fed by reverse osmosis processes reduce water consumption and protect the clean water supply. 

"I am thrilled with the teamwork employed to build this impressive new facility and even more excited about the career opportunities it creates," said Paul Underwood, Dura's Muscle Shoals Plant Manager.

"This was a truly collaborative effort with local and global technology experts working hand-in-hand to bring to life an amazing site that will be the foundation for additional job creation in our community."

Planning and construction of the new facility were completed in just eight months, leveraging the collaborative efforts of Dura technical teams, suppliers, and government officials.

INDUSTRY EVOLUTION

Dura's new Alabama facility is becoming operational as Mercedes prepares to begin building two luxury EV sport utilities at its 6 million-square-foot assembly plant in Tuscaloosa County this year.

"The opening of Dura's highly advanced EV battery enclosure manufacturing facility in Muscle Shoals reflects the expanding capabilities of the automotive supply chain for electric vehicle production in Alabama," said Greg Canfield, Secretary of the Alabama Department of Commerce.

"Our auto sector is fully focused on what the future holds for the industry and will continue to evolve to meet all challenges."

Aluminum structures & eMobility
Aluminum structures have been prominent in European premium vehicles to reduce mass, improving performance and fuel economy. As the market shifts toward electrified vehicles, lightweight architectures play a significant role in dramatically extending vehicle range and recharge intervals. Electric vehicle battery systems are integrated within a structural enclosure, often integral to the chassis system. Dura produces lightweight aluminum battery enclosures, complete with integrated cooling systems. The modules are precision manufactured and sealed to safely encapsulate components of the battery, control systems, and monitoring electronics. Each battery tray design is custom engineered and manufactured specifically to an automaker's performance objectives. The company has produced lightweight aluminum architectures for vehicles since 1990.

About DURA Automotive Systems
Dura Automotive Systems, a MiddleGround Capital Company, is a global automotive supplier specializing in the design, engineering, and manufacturing of solutions that drive the evolution of mobility. With a legacy comprising more than 100 years of inspired invention, the company is recognized by leading vehicle manufacturers as a preferred supplier partner for innovative, highly integrated mechatronic systems and lightweight structural solutions. Dura's forward-thinking technology roadmap includes mechatronic driver control systems, including shift-by-wire and electronic actuators; lightweight structural body systems, including electric vehicle battery enclosures; and a portfolio of precision manufactured automotive products. Dura is headquartered in Auburn Hills, Michigan, USA. Learn more at duraauto.com.