When Volvo Cars recently presented the new EX60, it marked more than the launch of a new vehicle model. It also signalled a clear technological shift in the global automotive industry. At the same time, it highlights an area in which research at Chalmers University of Technology is playing an increasingly important role.
Megacast body part for rear floor section of a Volvo EX60. Photo: Volvo Cars
One rear structure in a single piece
The EX60 will be the first Volvo model to use so-called megacasting. Instead of assembling the rear structure from 60 to 100 welded steel components, these are replaced by a single, large high-pressure die-cast aluminium structure. The result is fewer joining processes and lower manufacturing costs. The EX60 represents a clear European breakthrough, with production taking place at the Torslanda plant in Gothenburg.
More than a manufacturing method
Megacasting is not merely a production innovation, it can also give a strong push for sustainability. The technology places new demands on materials development, advanced simulation, and a deep understanding of thermal processes, structural performance and repairability. These are areas in which Chalmers has strong expertise.
In just 2.5 years, research in this field has grown from zero to a project portfolio of approximately SEK 50 million, with an annual volume of around SEK 10 million. Funding is provided by, among others, Vinnova through initiatives such as Net Zero Industry and FFI, as well as by Mistra, WISE, SSF and WISE/WASP.
“Our research focuses on developing circular materials solutions that make it possible to use more recycled aluminium in advanced, high-performance products. This is an important part of reducing both climate impact and resource use in the automotive industry. By combining modelling with experimental testing, we contribute to the development of new manufacturing technologies, such as megacasting, with a lower environmental footprint.
The growing interest from industry, together with our collaboration with Jönköping University and RISE, points to continued growth,” says Lars Nyborg, Professor of Surface Engineering at Chalmers University of Technology.
Opportunities for research and collaboration
Taken together, the Volvo EX60 illustrates how the industry’s transition towards electrification, simplified production and greater system integration is creating new research questions and new opportunities. For Chalmers, the focus is not on developing individual components, but on contributing the knowledge required to enable the next technological shift.
“This is a good example of how a large company takes responsibility for future development by engaging suppliers, universities and research institutes. Research and education strengthen competence and contribute to better products and increased competitiveness in the long term,” says Johan Ahlström, Professor of Materials Science at Chalmers University of Technology. Read more about the collaboration below.
The Swedish Broadcasting Corporation's Nyheter Väst asked Professor Johan Ahlström to explain how the technology works. Watch the videos below.
Watch a feature on SVT and Volvos introduction
- How Volvo Cars' new billion-pound machine works: ‘A highly advanced waffle iron?’ (Opens in new tab)
- What is megacasting? (Opens in new tab)
- What are the advantages? (Opens in new tab)
- What is the most difficult aspect of the technology? (Opens in new tab)
- What are the challenges ahead? (Opens in new tab)
- Introduction of Volvo Cars mega casting technology process (Opens in new tab)
Lars Nyborg
- Full Professor, Materials and Manufacture, Mechanical Engineering
Lars Nyborg
- Full Professor, Materials and Manufacture, Mechanical Engineering
Johan Ahlström
- Director of Studies, Mechanical Engineering
Johan Ahlström
- Director of Studies, Mechanical Engineering
