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

Volvo's EX60: A Revolutionary Electric SUV with Moose-Proofing and Megacasting

The automotive world is abuzz with the unveiling of Volvo's latest electric vehicle, the EX60. This mid-size SUV is a testament to the company's commitment to innovation, sustainability, and safety. With a focus on efficiency, technology, and unique design choices, the EX60 is poised to challenge its competitors.

Moose-Proofing: A Safety Revolution

One of the most intriguing features of the EX60 is its 'moose-proofing'. Volvo, a brand synonymous with safety, takes moose strikes very seriously, especially in its home country of Sweden. Moose, being large and unpredictable, pose a significant threat to drivers, particularly during low-light conditions. To combat this, Volvo employs a unique approach: life-size rubber moose crash test dummies.

These dummies are used to simulate moose collisions, allowing Volvo to design vehicles that can withstand such impacts. The EX60's A-pillars and header are designed to shield occupants from potential hazards, including moose. This attention to detail is a testament to Volvo's dedication to passenger safety.

Megacasting: A Lightweight Revolution

Another innovative feature is megacasting, a technique used to reduce weight, complexity, and environmental impact. Volvo's EX60 incorporates megacasting in its diecast rear floor, replacing over 100 parts with a single, efficient component. This 'buttress-like' structure, made from 50% recyclable aluminum, is a unique design choice that sets the EX60 apart.

Mats Brodin, a Volvo engineer, describes megacasting as an 'architectural' approach to vehicle design. The process involves forcing molten aluminum into a megacast machine in just 90 milliseconds, resulting in a lightweight, durable component. This technique is a significant departure from traditional manufacturing methods and showcases Volvo's willingness to push boundaries.

Smart Battery Integration and One-Pedal Driving

The EX60 also boasts a structural battery design, similar to the BMW iX3 and Tesla Model Y. This 'cell-to-body' integration reduces weight and improves range. The battery pack becomes the vehicle's floor, offering weight and packaging efficiency while opening up more cabin space. This design choice is a strategic move towards enhancing the overall driving experience.

During testing, the EX60's one-pedal driving feature impressed the author. The regenerative braking system, coupled with HuginCore, Volvo's proprietary software-defined vehicle platform, provides a smooth and responsive driving experience. This level of control and efficiency is a significant advantage in the competitive EV market.

Immersive Audio and AI Integration

The EX60's top-of-the-line model, the P10 Ultra, includes a 28-speaker Bowers & Wilkins sound system, delivering 1820 watts of three-dimensional Dolby Atmos sound. This immersive audio experience enhances the overall driving pleasure, especially for music enthusiasts who enjoy pounding rock genres.

Additionally, the EX60 incorporates conversational AI, allowing users to interact with the car using natural language commands. This feature, powered by Google Gemini, adds a layer of convenience and innovation to the vehicle's capabilities.

Conclusion: A Well-Rounded Electric SUV

In conclusion, the Volvo EX60 is a well-rounded electric SUV that showcases the company's commitment to innovation, sustainability, and safety. From moose-proofing to megacasting, smart battery integration, and immersive audio, the EX60 offers a unique blend of features that set it apart from its competitors.

As Volvo continues to innovate and refine its designs, the EX60 serves as a testament to the brand's ability to create vehicles that are not only environmentally friendly but also technologically advanced and aesthetically pleasing. The future of electric vehicles looks bright, and Volvo is undoubtedly at the forefront of this revolution.

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