Polestar 5 electric sports sedan set to use revolutionary bonded aluminium platform
Polestar is working on an entirely new, faster manufacturing process that develops both body and platform in unison.
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.
Polestar Precept given production green light; will be named Polestar 5
The Polestar 5 is a large luxury sedan, scheduled to enter series production in 2024. It should compete with premium electric heavyweights like the Porsche Taycan, Tesla Model S and Mercedes EQS and EQE.
The Polestar 5 is
Just look at it. The high waistline, that menacingly raked roofline. The Polestar 5 is one handsome beast. Derived from the Precept concept car in 2020, it’s pleasing to see not a huge amount has changed on the exterior of the vehicle from Polestar’s original concept.
The Precept was created to highlight the automaker’s broad and bold vision; one of sustainability including recycled materials for vehicle components as well as carbo n neutral vehicle production, of impressive performance and advanced safety, and of cutting edge in-vehicle technology. Such was the public response to this car that Polestar decided to green-light its production.
Polestar has revealed a little bit more about the Precept, in its multi-part online documentary series From Concept to Car. According to Thomas Ingenlath, Polestar CEO, “With the Precept documentary series we are intentionally doing something car companies usually don’t – going behind the scenes with transparency as we turn this stunning concept car into production reality. It makes me very proud to see how much of the concept car’s design is making it into the Polestar 5 – a great achievement by our designers and engineers alike,”
Exterior design cues from the Polestar 5 are also expected to tease the production version of the first full-size SUV from the brand, the Polestar 3. Not much is known about this car at the moment, except that it is scheduled to be revealed in 2022, and will run Polestar/Volvo’s dual motor AWD battery electric drivetrain.
The Polestar 3 will be a very important car for the brand, and will be manufactured in the United States - at least for the North American market - to go head to head with other luxury and internal combustion engined SUVs from the likes of Mercedes-Benz, Audi, Cadillac and Porsche.
The Polestar 5 is expected to be unveiled in late 2023, ahead of Northern Hemisphere customer deliveries in 2024.
Polestar’s Precept is the inspiration for the Polestar 5.
The Precept’s interior features many sustainable and recycled materials, but expect more conventional appointments in the finished production version.
Polestar doubles UK R&D team, shows off Precept EV prototype
The automaker announces the expansion of it’s UK R&D centre, with staff numbers expected to grow from 250 employees to 500. Polestar has also released an image of an early prototype Precept sedan.
The Polestar Precept development vehicle. Images: Polestar
Polestar has released this teaser image of the Precept sedan in development, and it’s the closest image we have seen yet of the final body design. A large, luxurious sedan, the Precept received so much positive acclaim after its worldwide reveal in 2020, that Polestar CEO Thomas Ingenlath announced the automaker would build it.
There’s one obvious change immediately apparent; the B pillar-less doors now features a B pillar; necessary for safety and side impact protection. While the Precept has a Tesla Model 3-esque silhouette in our view, it’s clear from the wheelbase that this is a much larger vehicle. Polestar has also stated that the Precept will remain true to the concept’s design as much as possible.
Gone are the “suicide” doors, replaced with conventional openings, though it appears the frameless design will remain.
Polestar’s Precept concept car
A two-tone diamond cut wheel is visible on the front axle, and appears to bear some resemblance to the concept’s wheels. It’s possible this design will make it to the production car. The rear wheel looks to be a prototype/testing wheel.
While we don’t have a firm release date on the Precept just yet, Polestar has communicated that production will start before 2025.
The manufacturer also announced an expansion of an R&D hub in the UK, with plans to increase its workforce from 250 employees to 500.
Polestar’s new facilities will be situated at the MIRA Technology Park in the heart of Motorsport Valley in the UK’s Midlands. MIRA Technology Park also offers access to a variety of specialised on-site equipment, including advanced battery testing, and an extensive test track network. A number of automotive engineering firms are located nearby.
“Going electric is a pivotal moment in the history of cars,” says Thomas Ingenlath, CEO of Polestar. “The combination of British engineering talent and Swedish expertise will ensure our cars are among the highest performing and most sustainable on the road.”
The UK team will work in conjunction with the main Swedish R&D team, to “focus on ground-breaking engineering solutions in a bid to help Polestar reach its goals” according to the company.
The development of the Precept will be the main project for the UK team, and Pete Allen, Head of Polestar UK R&D said “Precept is a statement of intent for the brand in terms of design, technology and sustainability. The production car will take an important step on the journey towards climate neutrality, and ours will be the team that delivers that.”
The expansion in R&D is required to help Polestar grow its model range;. Expect to see more on the Polestar 3 large SUV soon; this model will be crucial to growing the brand’s market share in countries like China and the United States.
