Volvo unveils EX60 electric SUV with 400-mile range and NACS port

Volvo has turned the EX60 into a test of whether a legacy automaker can use new manufacturing methods to cut EV costs fast enough to matter in the market’s most competitive segment. The all-electric midsize SUV, unveiled on January 21, 2026, is Volvo Cars’ first entry in what the company calls the largest electric segment globally, and it is being built as much around production efficiency as around range, charging and safety.

The EX60 sits on Volvo’s new SPA3 electric architecture and uses the HuginCore core system, with cell-to-body construction, in-house e-motors and core computing folded into the package. Volvo says the AWD version can travel up to 400 miles on a charge and recover up to 173 miles in 10 minutes on a 400kW fast charger. For U.S. buyers, the EX60 is also the first Volvo with a native NACS charging port, giving direct access to more than 25,000 DC fast chargers on the Tesla Supercharger network without an adapter. Volvo has paired that with a 10-year battery warranty.

The manufacturing story is just as important as the battery figures. Volvo says the EX60 is the first Volvo built with megacasting, a process that replaces hundreds of smaller parts with a single high-precision casting. Chalmers University of Technology said the EX60’s rear structure replaces 60 to 100 welded steel components with one large high-pressure die-cast aluminum part, lowering manufacturing cost and simplifying joining. Chalmers also said its megacasting-related research portfolio had grown to about SEK 50 million in 2.5 years, with annual funding around SEK 10 million, underscoring how closely the technology now ties into both industrial strategy and sustainability research.

Volvo has also leaned hard on safety. The EX60 introduces a new multi-adaptive safety belt that the company describes as a world-first safety technology, and the SUV is being sold as a five-seater family model meant to reduce range anxiety while delivering a new user experience. Preproduction testing took place at Volvo’s Hällered Proving Ground in Sweden, where engineering chief Anders Bell said the body was nearly as stiff as a Koenigsegg hypercar. The EX60 also used active noise cancellation for the first time in a Volvo, along with adaptive dampers with three settings.

Production of the EX60 began at Volvo’s Torslanda plant in Gothenburg on April 22, 2026, and Volvo said customer deliveries would start in early summer. In March, the company said it was increasing EX60 production volumes for 2026 after demand in Sweden, Germany and other key markets came in above projections. For Volvo, the EX60 is a bet that the next phase of the electric SUV market will reward not just range and charging speed, but the factory technology needed to deliver them at scale.