Polestar 5 electric sports sedan set to use revolutionary bonded aluminium platform
The Polestar 5 will closely resemble the Precept concept car.
The Polestar 5 — based on the Precept concept — is shaping up to be a technological tour-de-force, with the announcement from the automaker that the upcoming model will feature a revolutionary bespoke bonded aluminium platform.
Auto manufacturing is a constant juggling exercise, finding the fulcrum between low weight for efficiency and performance, and strength for safety. Aluminium is a lightweight material, but traditional welding techniques require additional metal for strength, somewhat negating the intended weight advantage. Bonded aluminium is light-weight and rigid, offering exceptional performance and “green” advantages, according to Polestar. We understand the process involves special adhesives and screws, rather than traditional welding.
According to Polestar, while this technology has previously proven labour-intensive and difficult to use in mass production vehicles without sacrificing quality, the company’s 280-strong team of former Formula 1, low volume and bespoke sports cars engineers in the UK have resolved the challenges associated with bonding technology by developing an entirely new, faster manufacturing process that develops both body and platform in unison.
Polestar 5 manufacturing process gallery
As a result of the new materials and techniques involved, the body-in-white (completed platform and body) is expected to weigh less than that of cars in smaller segments, contributing to improved vehicle efficiency, real-world EV range and dynamic responsiveness, all while delivering leading safety levels. The new bonded aluminium platform will also help drive faster product introduction, high quality and platform rigidity.
“Our UK R&D team is one of Polestar’s greatest assets,” says Thomas Ingenlath, Polestar CEO. “Their mix of engineering and technological expertise enables us to develop advanced, light-weight sports car technology with a creative mindset and a spirit that embraces innovative engineering. This will set Polestar apart in the years to come.”
By further developing this technology for Polestar’s first in-house platform, the 4-door Polestar 5 is being designed with torsional rigidity superior to that of a traditional two-seat sports- or supercar. The decision to develop a bespoke platform has also enabled the brand to deliver a production model that remains true to the Precept concept car that inspired it.
“We knew we wanted this car to be light-weight, we knew we wanted high quality and we knew we wanted it quickly,” says Pete Allen, Head of Polestar UK R&D. “This architecture delivers outstanding dynamic and safety attributes, with low investment technology applicable to high production volumes.”
Although without any distinguishing features in the above images, the Polestar 5 appears to retain the design character of the Polestar Precept concept, visible in the long hood, raked rear design and cut-off rear decklid. It also appears to be quite a large vehicle, when seen alongside a Polestar employee.
We expect the production Polestar 5 to be unveiled late 2022 - early 2023, ahead of a global market introduction in 2024.