How Navistar produces trucks in San Antonio: Photo gallery

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Picture this. Navistar has established a new manufacturing facility in San Antonio, Texas, integrating an array of advanced production techniques and tools to create combustion-driven and battery-electric Class 6-8 trucks.

These images offer an inside look at the production process and several of the underlying steps used to produce a Navistar truck.

Navistar San Antonio manufacturing plant
The Navistar San Antonio Manufacturing Plant covers nearly 1 million square feet. (Photo: Navistar)
Navistar San Antonio ribbon cutting
Navistar officially cut the ribbon to its San Antonio Manufacturing Plant on March 23. (Photo: John G. Smith)
Navistar robotics
Fanuc robotic welders automate the construction of a vehicle body by welding prefabricated components, creating the vehicle cab. (Photo: Navistar)
Navistar truck cabs
Painted cabs move along a conveyor line between Navistar’s paint shop and general assembly building in San Antonio, Texas. (Photo: Navistar)
automated guided vehicles
Automated guided vehicles (AGVs) move cabs and engines throughout Navistar’s plant in San Antonio, Texas. (Photo: Navistar)
engine assembly
An engine is dropped into position along the assembly line in San Antonio, Texas. (Photo: John G. Smith)
axle on frame
Navistar employees keep components on the move using a combination of hoists and AGVs. (Photo: John G. Smith)
Navistar AGV
Trucks in various stages of production glide along Navistar’s assembly lines while supported on AGVs. (Photo: John G. Smith)
Navistar paint booth
Paint booths at Navistar’s San Antonio manufacturing facility have minimal overspray, optimizing paint and reducing product waste. (Photo: Navistar)
Navistar truck wheel
Workers install a brake drum on a vehicle as it takes shape on Navistar’s assembly line in San Antonio, Texas. (Photo: Navistar)
Navistar truck frame
This vehicle frame is aligned upside down to secure the axles to the frame. (Photo: Navistar)
paperless manufacturing processes
One thing you won’t find at Navistar’s manufacturing operation is paper. The facility is paperless. (Photo: Navistar)
Navistar powertrain
Finishing touches are added along the powertrain trim-on line. (Photo: Navistar)
Navistar eMV Series electric truck
Truck models to be produced in San Antonio, Texas, include the battery-electric Navistar eMV Series and other Class 6-8 models. (Photo: Navistar)
Navistar plant
Once fully online, the Navistar plant will be able to produce 52 trucks per day. (Photo: John G. Smith)
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John G. Smith is Newcom Media's vice-president - editorial, and the editorial director of its trucking publications -- including Today's Trucking,, and Transport Routier. The award-winning journalist has covered the trucking industry since 1995.

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  • One question has anyone looked at the cost of the Battery’s for the eMV electric Class 6 & 8 Trucks and Tractor’s?
    I have been asked for replacement of these are very expensive?
    I have had some customers ask this question and nobody can give me an answer to this question.