how are electric cars made

[LeAubrey]

Electric cars are manufactured through a highly automated process that revolves around three core components: the battery pack, the electric motor, and the power electronics. Unlike traditional cars that require an engine and transmission, the fundamental simplicity of an EV's powertrain allows for a different assembly line approach. The process begins with sourcing and producing the lithium-ion battery cells, which are then assembled into large modules and combined into a complete battery pack, the vehicle's most expensive single part.

The chassis, or "skateboard" platform, is designed specifically to integrate this large, flat battery pack into the floor, providing a low center of gravity. The electric motor or motors are mounted directly to the axles or chassis. Meanwhile, the car's body is built on a separate line through stamping, welding, and painting. The major assembly happens when the body is lowered onto the completed skateboard chassis. Finally, the interior, software, and extensive testing ensure everything from the infotainment system to the thermal management system (which regulates battery temperature) works flawlessly before the car is shipped.

Here is a comparison of key data points from different stages of EV manufacturing:

Manufacturing Component	Typical Data Point	Description / Significance
Battery Cell Energy Density	250 - 300 Wh/kg	The amount of energy stored per kilogram; higher density means longer range.
Gigafactory Annual Output	500,000+ battery packs	Scale of production at massive dedicated EV battery plants.
Body Shop Automation	90 - 95%	The percentage of welding and assembly tasks performed by robots.
Paint Shop Curing Temperature	140°C - 160°C (284°F - 320°F)	High temperatures ensure paint durability and finish quality.
Powertrain Assembly Torque	80 - 120 Nm	The precise torque applied to bolts securing the motor and reduction gear.
Final Inspection Checkpoints	200 - 500 points	The number of individual items inspected before a car is cleared for delivery.
Battery Pack Cooling	Liquid-cooled vs. Air-cooled	Liquid cooling is more common in high-performance and long-range models for better temperature control.
DC Fast Charging Capability	10-80% in 20-30 minutes	The charging speed supported by the vehicle's onboard charger and battery management system.

[Cayden]

From my visits to plants, it's like a choreographed dance of robots. The body gets welded together in a shower of sparks, then it's dipped, painted, and baked. The cool part is when the smooth, silent skateboard—loaded with the battery and motor—rolls in. They just lower the finished body right onto it. It's a much cleaner process than an engine plant, and the quietness of the final product starting up for the first time is always striking.