New Architecture and Over 500 Miles of Range: Volvo EX60

The EX60 will sit squarely between the compact EX40 and the flagship EX90 in Volvo’s electric lineup. According to project lead Achil Krishnan, the new model is designed to outperform not only earlier Volvo EVs but also many of today’s competitors in the premium electric segment.

One of the EX60’s standout advantages is efficiency. Even in all-wheel-drive form, the crossover is expected to deliver up to 505 miles of range on the WLTP cycle. Thanks to a new 800-volt electrical architecture, charging times should be among the fastest in its class. When connected to a 400 kW DC fast charger, the EX60 can add roughly 210 miles of driving range in just 10 minutes.

Unlike conventional electric vehicles, where battery modules are mounted inside a separate enclosure, the EX60 uses a cell-to-body design. Individual battery cells are integrated directly into the vehicle’s floor structure. This reduces overall weight and increases rigidity, as the battery pack also serves as a structural element of the chassis.

The EX60 also introduces Volvo’s new SPA3 platform, which represents a major step forward compared to the architecture used by the EX90. The body is built using large aluminum megacastings for the wheel arches and underbody. This approach replaces dozens of welded steel panels with a single, monolithic structure, significantly reducing weight while improving structural stiffness.

Despite its strong focus on aerodynamic efficiency, Volvo chose not to give the EX60 an extreme, teardrop-shaped profile. Instead, the crossover retains the brand’s familiar clean lines and a spacious cabin. Drag reduction is achieved through intelligent design of the front fascia and underbody rather than radical exterior styling.

Battery management software from UK-based Breathe Battery Technologies monitors the temperature of each individual cell. This allows for faster charging while also extending battery lifespan. Volvo is confident enough in the system to offer a warranty of 10 years or 150,000 miles, with at least 70 percent of the battery’s original capacity guaranteed.

The new Volvo EX60 will be produced alongside the updated XC60. However, it was developed as a dedicated electric vehicle from the outset, allowing engineers to fully optimize interior space and packaging.