UK team develops bonded aluminium process for Polestar 5

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Polestar’s UK R&D team at MIRA Technology Park have developed a bonded aluminium manufacturing process for the upcoming Polestar 5 electric performance 4-door GT.

bonded aluminium
(Image: Polestar)

Vehicles made with mixed metal structures are bonded with welds and around 3,500-4,000 rivets compared to bonded aluminium unibody technology that uses adhesive and oven curing to join parts. The process results in a structure that is lightweight and rigid, but it is also labour-intensive and challenging to scale up without sacrificing quality. Consequently, bonded aluminium has been restricted to low-volume performance cars.

Now, Polestar said its 280-strong team have resolved this challenge by developing an entirely new, faster manufacturing process that develops the body and platform in unison.

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As a result of the new materials and techniques involved, the body-in-white is expected to weigh less than that of cars in smaller segments, contributing to improved vehicle efficiency, real-world EV range and dynamic responsiveness. The new bonded aluminium platform will also help drive faster product introduction, high quality and platform rigidity.

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