Ford invests $2 billion to convert Louisville plant for new electric truck

Ford Motor Co. disclosed a $2 billion transformation of its Louisville Assembly Plant to build the Fathom midsize electric truck beginning in 2027. The overhaul adopts the company’s Universal EV Production System, which reorganizes assembly into three main sections—front, rear and battery deck—allowing parallel work and faster build times. Large aluminum castings will substitute dozens of smaller stamped and welded components, and the wiring harness will be shorter and lighter than in earlier electric models.

The plant’s Wi-Fi access points will increase from 385 to 1,080, and automation will reach the highest level among Ford’s factories. Employees are being trained in Michigan on the new workflow, which aims to reduce reaching motions and simplify tasks. Prototype production is slated for the first quarter of 2027, with full truck output later that year.