Polestar Develops Cheaper Bonded Aluminum Construction for 5 – Roadshow [CNET]

Bonded aluminum construction is no longer solely the province of the expensive or exotic, thanks to new tech from Polestar.

1 of 12 Polestar

Polestar’s UK R&D facility has developed new construction tech for the forthcoming Polestar 5.

2 of 12 Polestar

The tech is based on bonded aluminum construction.

3 of 12 Polestar

Bonded aluminum chassis construction has been around for decades in sports cars and exotics.

4 of 12 Polestar

It has the benefit of being lightweight and strong, but it’s expensive.

5 of 12 Polestar

The expense comes from the labor-intensive nature of the construction process.

6 of 12 Polestar

Polestar found a way to remove steps in the construction process, reducing the labor needed.

7 of 12 Polestar

This will allow the Polestar 5 to benefit from a light and rigid chassis without being brutally expensive.

8 of 12 Polestar

The benefits of a light and rigid chassis are well-documented.

9 of 12 Polestar

But those benefits are even more pronounced in an EV.

10 of 12 Polestar

Less weight means more range without bigger batteries, and that’s always good.

11 of 12 Polestar

The Polestar 5 will use bonded aluminum construction.

12 of 12 Polestar