Building a car with 100% USA-made parts isn’t practical today, and each step closer adds thousands of dollars, analysts and executives told CNBC on May 16, 2025.
What CNBC found
- A 2025 Ford Expedition assembled at Ford’s Kentucky Truck Plant has at least 58% of its main parts from outside the country, including 22% from Mexico, according to its window sticker.
- One expert estimated it could cost $5,000 more to raise a vehicle from under 70% USA and Canadian parts to 75-80%. Reaching 90% could cost another $5,000 to $10,000.
- AlixPartners’ Mark Wakefield said about 95% is the practical limit today. An all-USA car at scale would take 10-15 years and $100 billion. A low-volume one could cost $300,000-$400,000.
- Vehicles at 75% or more USA/Canadian parts for 2025 include the Kia EV6, two Tesla Model 3 versions and the Honda Ridgeline AWD Trail Sport, according to NHTSA data.
- In 2007, the top 16 vehicles all had 90% or more USA and Canadian content.
“The cost gets quantumly more … the closer you get to 100%.”
Mark Wakefield, AlixPartners
Why it matters for Made in USA
The window sticker’s parts figure combines USA and Canadian content, so it isn’t a Made in USA measure. Even cars assembled in the USA rely on imported engines, chips and raw materials. Shoppers who want more USA content can use the sticker and indexes such as Cars.com’s. Related: Cars.com’s 2025 index.
FAQ
Is there a 100% USA-made car?
No. Experts told CNBC about 95% is the practical limit at the moment.
What would an all-USA car cost?
At low volume, possibly $300,000-$400,000. At scale, the industry would need 10-15 years and about $100 billion.
Where can I see a car’s parts content?
On the window sticker, which lists USA and Canadian parts content under the American Automobile Labeling Act.
Source & credit
Source: CNBC, May 16, 2025: “How much would a 100% ‘Made in the USA’ vehicle cost? It’s complicated”, by Michael Wayland.