EX60 by Volvo Cars: status and timeline

EX60

Deploy megacasting at scale in production vehicles, reducing weight and assembly complexity while transitioning to electric powertrains.

DeployStage 4 of 5

Production underway at Torslanda since April 2026; customer deliveries ramping through 2026.

Updated Apr 2026Checked 11 Oct0 updates this week

Milestones

Next · Production ramp-up to full capacity

Torslanda factory modernization investment announced2023Complete.
Start of EX60 production at TorslandaApr 2026Complete.
Early customer deliveries beginJul 2026Complete.
Production ramp-up to full capacityTarget Q4 2026Not yet reached.

Most important updates

Volvo Cars begins production of EX60 at Torslanda with megacasting technologyApr 2026

Upcoming

Q4 2026Production ramp-up to full capacity (next)

Current obstacles

Casting defect ratesInternal porosity and shrinkage voids compromise structural integrity; defect detection challenging at scale.
Production ramp challengesOrders exceeded forecasts; ramping requires better yield and supply chain optimization.

Physics limits

Aluminum fatigue under stressAluminum is lighter and cheaper than steel but has lower fatigue strength. A rear axle casting must withstand millions of compression and torsion cycles; this limits design freedom.
Heat management in large castingsCooling a large part uniformly takes time, and uneven cooling causes residual stress and warping. This sets the lower bound on cycle time and press tonnage.
Scrap recoveryLarge castings that fail inspection cannot be easily reworked. Scrap must be melted and recast, adding cost; yield targets drive tooling investment and process discipline.

How it works

3 parts

Design integration

Structural megacast rear axle

One aluminum casting integrates suspension mounting, rigidity and crash protection.

Manufacturing process

High-pressure aluminum casting

8,400-tonne presses force molten aluminum into a mold, creating one part in place of assembly.

Supply chain simplification

Fewer suppliers and logistics

One megacast replaces parts from multiple suppliers, reducing incoming inspection, inventory, and assembly labor while shortening time-to-market.

Spec sheet

Spec	EX60
Powertrain	Battery electric^R (reported)
Parts replaced by rear axle megacast	~170 individual parts^R (reported)
Torslanda factory investment	Approximately EUR 870 million^R (reported)
Press capacity for megacasting	8,400 tonnes^R (reported)
Production location	Torslanda, Gothenburg, Sweden^R (reported)

^R reported by the company

Update log

1 update

Apr 2026

Major: Volvo Cars begins production of EX60 at Torslanda with megacasting technologyPressManufacturing

About Volvo Cars

The team behind EX60

Volvo Cars

Swedish carmaker, electric vehicles, megacasting, safety

Volvo Cars is a Swedish carmaker producing luxury SUVs, sedans and station wagons. Founded 1927, owned by Geely since 2010, and public since 2021.

Sweden's leading automaker, known for safety and now focused on electrification.
In 2026, EX60 production began at Torslanda using megacasting for the rear underbody.
EX60 is Volvo's first fully electric car designed and built entirely in Sweden.

volvocars.com (opens volvocars.com)Company profile →

Founded: 192799 yrs
Headquarters: Sweden
Status: Public
Valuation: public
Staff: ~42,600Jan 2025
Works in: ManufacturingGigacastingVehicles
Coverage: 1 program · 1 updatelatest 1 Apr 2026checked 11 Oct
Partners: Polestar (opens polestar.com)
Investors: Geely Holding (opens geely.com)

Spec

EX60

Powertrain

Battery electric^R (reported)

Parts replaced by rear axle megacast

~170 individual parts^R (reported)

Torslanda factory investment

Approximately EUR 870 million^R (reported)

Press capacity for megacasting

8,400 tonnes^R (reported)

Production location

Torslanda, Gothenburg, Sweden^R (reported)