Volvo EX60 Ushers In A New Era Of Prismatic, Structural EV Batteries

Volvo is preparing to launch what could be its most important EV yet: the EX60, a mid-size electric SUV that blends cutting-edge software with next-generation battery technology. Due to arrive in the U.S. and global markets next year, the EX60 is set to showcase a leap forward in energy storage, efficiency, and structural integration.

Dual-Chemistry Battery Strategy

Volvo’s Chief Technology Officer, Anders Bell, confirmed in an interview that the EX60 will offer two battery chemistries, continuing a strategy first seen on the smaller EX30. While exact specifications are still under wraps, lithium-iron phosphate (LFP) batteries are “absolutely on the table” for the EX60’s SPA3 platform, alongside higher-performance nickel-manganese-cobalt (NMC) packs.

This dual-chemistry approach gives Volvo flexibility: affordable LFP packs for value-oriented buyers and higher-density NMC options for drivers prioritizing range. In Europe, the EX30 already offers a 51-kWh LFP pack and a 69-kWh NMC pack, though only the latter is available in the U.S. A similar playbook could unfold with the EX60.

Prismatic Cells: The Big Shift

Perhaps the most transformative upgrade is Volvo’s shift to large-format prismatic cells. Unlike cylindrical cells favored by Tesla, prismatic cells are shaped like rectangular blocks—think “a VHS cassette, but bigger,” as Bell put it.

This cell format delivers several benefits:

• Greater flexibility in chemistry—manufacturers can swap LFP, NMC, or even emerging lithium-manganese-rich (LMR) chemistries into the same form factor.

• Improved packaging efficiency—more energy can be stored without increasing the size of the pack.

• Weight and cost savings—fewer components and simpler assembly.

Automakers beyond Volvo are adopting the same approach. Volkswagen plans to roll out prismatic cells for its affordable EVs starting next year, while General Motors has announced prismatic batteries for its full-size SUVs and trucks by 2028.

Cell-to-Body Integration

The EX60 will also adopt cell-to-body battery integration, meaning the battery will serve as a structural element of the SPA3 platform rather than a separate bolt-on unit. This design increases rigidity, simplifies manufacturing, and frees up space for larger battery packs. It’s a leap that echoes strategies used by Tesla and BYD, both of which have demonstrated how structural batteries improve efficiency and reduce costs.

Beyond Batteries: Smarter Hardware

While batteries are the headline story, the EX60 isn’t stopping there. It will also feature:

• Nvidia Drive Thor AI computer—capable of an astonishing 1,000 trillion operations per second, enabling advanced driver-assist and software-defined features.

• Third-generation Volvo drive units—with efficiency rated at 93%, pushing the limits of energy use in EV drivetrains.

These upgrades align with Volvo’s broader turnaround plan, which emphasizes both cutting-edge software and mechanical refinement to stay competitive in the premium EV market.

Production and Market Positioning

The EX60 will be built at Volvo’s main plant in Gothenburg, Sweden, with global sales expected to begin next year. Positioned squarely against rivals such as the Tesla Model Y, BMW iX3, and Mercedes-Benz EQC successor, the EX60 has the potential to become Volvo’s most important EV to date.

By combining advanced prismatic batteries, dual-chemistry flexibility, and structural integration, Volvo is betting on a package that balances cost, efficiency, and driving range—three critical factors in the next phase of EV adoption.

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