What plant makes the Chevy Bolt?

The Chevy Bolt is built at General Motors' Orion Assembly Plant in Orion Township, Michigan. This article explains where the Bolt is made, the facility's role, and what models it produces.

Production site

Orion Assembly is GM's Michigan facility that has served as the home for the Bolt since the program's inception. Located in Orion Township in Oakland County, the plant sits roughly 25 miles north of Detroit and is a cornerstone of GM's electric-vehicle manufacturing efforts.

Key facts about the production site are summarized below.

• Location: Orion Assembly Plant, Orion Township, Oakland County, Michigan, about 25 miles north of Detroit.


• Models produced: Chevrolet Bolt EV and Bolt EUV (electric versions of the brand's compact hatchback line).


• Operator: General Motors. The plant is operated by GM as part of its electrification push.


• Production start: Bolt production began at Orion Assembly for the 2017 model year, with the Bolt EV rolling off the line in 2016.

Together, these facts illustrate Orion Assembly’s central role in GM's lineup of affordable, all-electric vehicles and its position in Detroit’s broader EV manufacturing ecosystem.

Milestones in Bolt production at Orion

A concise timeline shows how Bolt production evolved at the Orion plant and what it has meant for GM's EV strategy.

• 2016–2017: Production begins for the first-generation Bolt EV at Orion Assembly in anticipation of the 2017 model year.


• 2021–2022: Bolt EUV joins the lineup, produced on the same Orion line for the 2022 model year and beyond.


• Ongoing: The plant continues to produce Bolt EV and Bolt EUV as part of GM’s broader electrification push in North America.

These milestones underscore Orion Assembly's role as a long-running hub for Chevrolet’s electric hatchbacks and a proving ground for GM's mass-market EV strategy.

Summary

The Chevy Bolt is manufactured at GM’s Orion Assembly Plant in Orion Township, Michigan. The facility handles Bolt EV and Bolt EUV production, serving as a cornerstone of GM’s strategy to expand affordable electric mobility in the United States.

Where is Chevy Bolt manufactured?

The final assembly of the Chevy Bolt EV and EUV took place at the GM Orion Assembly plant in Lake Orion, Michigan, until production ceased in December 2023. However, the next-generation Chevy Bolt, which will be built on GM's Ultium platform, is scheduled to be manufactured at the GM Fairfax Assembly plant in Kansas. 

• Past production: The original Chevy Bolt EV and EUV were assembled at the GM Orion Assembly plant in Lake Orion, Michigan. 
• Future production: The next-generation Chevy Bolt is slated for production at the GM Fairfax Assembly plant in Kansas. 
• Component manufacturing: Some components, like the battery cells, motor, and other parts, were manufactured by LG in South Korea and in other locations in Michigan. 

Why is Chevy discontinuing the Bolt?

Why Are These Chevy Bolt Models Being Discontinued? The reason why the Chevy Bolt models are ending production is because of their batteries. Chevrolet is making a significant investment in Ultium®-based platforms. The upcoming Chevy Blazer EV and Chevy Equinox EV use this newer, more advanced architecture.

What car is replacing the Chevy Bolt?

Transitioning our focus to the upcoming 2024 Chevy Equinox EV, this innovative compact crossover SUV, destined to replace the discontinued Bolt, elevates its prowess by offering alternatives between Front-Wheel Drive (FWD) and All-Wheel Drive (AWD).

How much does it cost to replace a Bolt EV battery?

A Chevy Bolt battery replacement can cost between $12,000 and $17,120, with the bulk of the cost being the battery pack itself ($16,250 estimate) and the rest for labor. While some sources quote around $16,000 for the battery pack, prices fluctuate, and individual battery cells are a cheaper alternative at about $990.81 per cell, though this is not ideal for a worn-out battery. 
Cost breakdown

• Battery Pack: The replacement battery pack is the main expense, with estimates for the pack alone in the range of $16,000 to $17,100. 
• Labor: Labor costs vary but are estimated at around $870 for a typical replacement, though more complex issues can increase this amount significantly. 
• Individual Cells: Chevy Bolt battery packs are made of individual cells, and while a single cell replacement is cheaper ($990.81), it's generally not a viable long-term solution for a battery that is nearing the end of its life. 

Factors that affect the cost

• Battery Size: The size of the battery pack is the primary factor in its cost. Newer Bolt models have a 66-kWh pack, while older models have a 60-kWh pack. 
• Labor Rates: Labor rates can range from $150 to $200 per hour at a GM dealership. 
• Damage: Damage to the old battery or surrounding system can increase the cost of labor. 
• Used vs. New: The price of used batteries can range from $5,000 to $9,000 but the capacity and power are unknown, so caution is advised. 

You can watch this video to learn more about the cost of EV battery replacement: 1mThe Electric VikingYouTube · Apr 3, 2023
Alternatives

• Used Batteries: You can find used batteries in the $5,000 to $9,000 range, but their condition and warranty are unknown, making this a risky option. 
• Individual Cells: It is possible to replace individual battery cells for a lower cost, but this is generally not recommended for a worn-out battery pack.