Volvo EX60: Megacasting, Moose-Proofing, and More! | Ars Technica Review (2026)

Let's dive into the world of automotive innovation with a focus on Volvo's latest offering, the EX60. This all-electric SUV is more than just a car; it's a testament to Volvo's commitment to efficiency, safety, and cutting-edge technology.

The EV Revolution: Volvo's Approach

Volvo has taken a bold step into the future with the EX60, showcasing its ability to adapt and thrive in the evolving automotive landscape. The EX60 is not just another electric vehicle; it's a statement of Volvo's expertise and vision.

One of the most intriguing aspects is Volvo's claim that it has revolutionized its production process for this model. From megacasting to cell-to-body battery integration, every detail has been refined. This approach not only enhances efficiency but also sets a new standard for EV manufacturing.

Moose-Proofing: A Unique Challenge

Now, here's where things get really interesting. Volvo, being a Swedish brand, has had to tackle a unique safety concern: moose collisions. Yes, you read that right! Sweden's largest land mammal poses a significant threat to drivers, especially during dusk and dawn.

Volvo's solution? A life-size rubber moose crash test dummy. Every Volvo model, including the EX60, undergoes this test, ensuring that drivers are as prepared as possible for a potential moose encounter. It's a fascinating insight into the lengths automakers go to ensure safety.

Megacasting: A Revolutionary Technique

Megacasting is a game-changer in the automotive industry. Volvo has adopted this technique, which involves converting molten aluminum into lightweight, single-piece components. This not only reduces weight and complexity but also has environmental benefits.

The EX60's rear floor, for instance, is a masterpiece of megacasting. It replaces over 100 parts with a single efficient component, a true testament to Volvo's engineering prowess.

Smart Battery Integration

Volvo's EX60 boasts a 'cell-to-body' battery design, similar to that of a BMW iX3 or Tesla Model Y. This innovative approach integrates the battery cells directly into the vehicle's body, creating a seamless and efficient package.

The result? Improved weight distribution, increased cabin space, and enhanced range. It's a perfect example of how Volvo is pushing the boundaries of EV design.

One-Pedal Driving: A Smooth Experience

During my test drive of the EX60, I was impressed by its one-pedal driving capabilities. The regenerative assets of the vehicle made for a smooth and enjoyable experience, especially on twisty roads.

Volvo has managed to create a one-pedal drive that is not jerky or difficult to adapt to, a common issue with many EVs. This speaks volumes about Volvo's attention to detail and driver comfort.

HuginCore: The Brain of the EX60

The EX60's brain, HuginCore, is a proprietary software platform that enables over-the-air updates with minimal disruption. Named after a mythological Norse raven, HuginCore also powers the Google Gemini AI engine, allowing for natural conversations with the car.

Imagine asking your car to adjust the temperature, and it responds like a friend. This level of conversational AI is a game-changer and adds a whole new dimension to the driving experience.

Audio Excellence

The top-of-the-line EX60 P10 Ultra features a jaw-dropping 28-speaker Bowers & Wilkins audio system. The sound quality is immersive and exceptional, catering to a variety of music genres.

Whether you're a fan of heavy rock or prefer a more mellow sound, the EX60 delivers an audio experience that is truly second to none.

A Thoughtful Conclusion

Volvo's EX60 is a masterpiece of engineering and innovation. From its unique safety features to its cutting-edge technology, it's clear that Volvo has created an EV that is not just a car, but a statement of its brand's values and expertise.

As we move further into the EV era, it's exciting to see automakers like Volvo pushing the boundaries and offering us a glimpse into the future of automotive design and technology.

Volvo EX60: Megacasting, Moose-Proofing, and More! | Ars Technica Review (2026)
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