Although Volvo has not yet confirmed whether the EX60 will feature the same LiDAR external sensor technology as the EX90, the company is currently testing various new safety systems and sensors. It remains unclear if these innovations will be available by the time the EX60 launches. Visually, the EX60 is expected to draw several elements from both the compact EX30 and the large EX90. Buyers can expect the same 8-bit-style Thor’s-hammer LED headlights as both of those cars, as well as features like flush door handles, a blanked-off grille and aerodynamic alloy wheels.
While the specific battery size for the EX60 has not been disclosed, we do know it will include a new “structural” battery pack designed to improve both energy density and structural integrity by being integrated into the car’s floor.
Moreover, the EX60’s floor will be megacasted, meaning it will be manufactured from a single piece of aluminum. At present, Tesla is the only other mainstream manufacturer employing this technique. Megacasting is faster than traditional manufacturing methods and can lead to significant weight reductions. Volvo also aims to make these megacasted floor pans fully recyclable at the end of the vehicle's life. Volvo will introduce mega-casting into the production of its next-generation electric cars, due in 2026 – a move it says will greatly improve efficiency and create more freedom for future vehicle design and manufacturing.
The firm says the advanced manufacturing process will be introduced on the next-generation EVs produced at its main Torslanda plant in Sweden.
We expect the new Volvo EX60 to debut in 2025, following the EX90’s scheduled release in late 2024. However, an official unveiling might take place before the end of this year.
