Design and engineering
The process starts with designing the vehicle, including its overall structure, aerodynamics, interior layout and more. Engineers and designers work together to create a blueprint that considers factors such as performance, safety, aesthetics and energy efficiency.
Chassis and body construction
The vehicle's chassis (frame) is typically made from lightweight materials like high-strength steel, aluminium, or sometimes carbon fibre. The body panels are also constructed using these materials. These lightweight materials help improve the vehicle's efficiency and range.
Battery manufacturing
The battery pack is one of the most critical components of an EV. It's made up of individual lithium-ion battery cells that are connected together to provide the required voltage and capacity. Battery manufacturing involves assembling the cells, adding management systems for temperature control and balancing and enclosing the entire pack in protective casing.
Motor and powertrain assembly
The electric motor and associated power electronics are assembled separately from the battery. The motor provides the propulsion for the vehicle. The power electronics manage the flow of electricity between the battery and the motor. These components are typically located near the axles of the vehicle.
Interior and electronics installation
The vehicle's interior components, such as seats, dashboard, infotainment system and wiring harnesses, are installed. Advanced EVs also include sophisticated electronics for monitoring battery health, managing regenerative braking and controlling various vehicle systems.
