Polestar 5: Body and platform made from bonded aluminum parts

The Polestar team has developed an innovative manufacturing process in which the body and platform are produced simultaneously. The leading development center was only opened in 2019 and initially started with 60 employees. The team now consists of 280 former Formula 1, small series, and sports car engineers and has initiated the new manufacturing process in the heart of the British Motorsport Valley in the Midlands. In the coming months, the specialist team is expected to grow to around 500 engineers.

"We want this car to be light, meet our high quality standards, and, above all, we want to realize it as quickly as possible," explains Pete Allen, Head of Research and Development at Polestar UK, describing the challenge. "This architecture offers outstanding dynamic and safety-related properties with a technology that can be applied to high volumes with low investments."

Aluminum offers performance and environmental benefits

“Our UK research and development team is one of Polestar's greatest assets,” said Thomas Ingenlath, CEO of Polestar. “The blend of technical and technological expertise within the team allows us to develop advanced lightweight technology with creative and innovative engineering. This will set Polestar apart in the coming years.”

Thanks to the new technology, the body-in-white (complete platform and body) is supposed to weigh less than that of smaller models. This is expected to contribute to improved vehicle efficiency, leading to greater range and a dynamic response. At the same time, Polestar places great emphasis on maintaining the brand's high safety standards. The new bonded aluminum platform also ensures faster product launches. A body made from bonded aluminum parts is both lightweight and robust. However, this technique has so far proven to be labor-intensive and challenging. Consequently, it has found little use in mass vehicle production up to now.