Volvo Cars has revealed its upcoming EX60 electric SUV will deliver up to 810 kilometres of range on a single charge, positioning it as the longest-range electric vehicle in the brand’s history and a direct assault on one of the biggest barriers to EV adoption.
The Swedish automaker’s announcement, made two weeks ahead of the EX60’s global debut on January 21, 2026, targets what Chief Technology Officer Anders Bell calls “the end of range anxiety.” The figure represents a WLTP-certified range for an all-wheel-drive configuration, not a stripped-down single-motor variant, making the claim particularly significant in the competitive mid-size electric SUV segment.
Revolutionary SPA3 Architecture: Cell-to-Body Integration
The EX60’s breakthrough performance stems from Volvo’s new SPA3 electric vehicle architecture, the company’s most advanced EV platform to date. Unlike conventional EVs that house battery cells in separate modules within a protective case, SPA3 integrates the battery directly into the vehicle’s structure using cell-to-body technology. This approach eliminates redundant packaging, reduces overall weight, and improves structural rigidity.
Volvo has complemented this with several weight-saving innovations. The EX60 becomes the first production Volvo to utilise ‘Megacasting’—a manufacturing process that replaces hundreds of smaller components with single, high-precision castings. This technique not only simplifies production but also creates lighter parts, directly contributing to the extended range.
The battery itself features a new cell design that Volvo says “carefully balances energy density and power delivery.” While the company hasn’t disclosed the exact energy content, industry analysts estimate it will be around 108 kWh net capacity, similar to the BMW iX3, which achieves approximately 600 km range. The EX60’s superior efficiency comes from its integrated design and in-house developed electric motors, which optimise energy conversion throughout the drivetrain.
800V System Enables Ultra-Fast Charging
Perhaps equally impressive as the range figure is the EX60’s charging capability. The 800-volt electrical architecture, combined with proprietary software developed in-house, allows the EX60 to add up to 340 kilometres of range in just ten minutes when connected to a 400-kW DC fast charger. This translates to roughly 173 miles of EPA-rated range in the same timeframe.
Volvo emphasises that this charging performance will be consistent “in all weather conditions,” suggesting advanced thermal management and battery preconditioning systems. The company has partnered with Breathe Battery Technologies, a portfolio company specialising in adaptive charging algorithms that optimise battery performance across different temperatures and usage patterns.
For context, the EX60’s charging speed exceeds even the ES90 sedan’s 350 kW maximum, though Volvo hasn’t specified the exact peak charging power or the time required for a 10-80% charge. These details are expected at the official debut.
Market Positioning: Direct Challenge to Segment Leaders
The EX60 enters a crowded mid-size electric SUV market dominated by the Tesla Model Y, which currently offers up to 357 miles (574 km) of EPA range. However, Volvo’s 810 km WLTP claim (approximately 503 miles) would surpass even the long-range Model Y and Chinese competitors like the Zeekr 7X, which also advertise ranges above 800 km.
Akhil Krishnan, head of Volvo’s EX60 program, told Reuters the development team focused specifically on customer concerns about electric vehicle ownership. “We wanted to look at the challenges the customers face in order to own and use electric vehicles, and range anxiety is one of those key things that we wanted to tackle,” he said.
The vehicle’s positioning suggests Volvo aims to attract buyers who might otherwise choose combustion-engine SUVs for long-distance travel. With 810 km range, the EX60 could theoretically drive from Paris to Amsterdam, Los Angeles to San Francisco, or Stockholm to Oslo on a single charge—distances that cover most customers’ typical long-journey needs.
Design and Manufacturing Innovations
Beyond the technical specifications, the EX60 represents a manufacturing evolution for Volvo. The Megacasting process reduces assembly complexity by eliminating hundreds of welding and fastening operations, potentially improving quality consistency while reducing production time.
The cell-to-body battery integration not only saves weight but also creates a lower centre of gravity, which should improve handling characteristics. Volvo’s in-house motor development suggests tighter integration between hardware and software, enabling more sophisticated energy management strategies.
All EX60 customers will receive a 10-year battery warranty, indicating Volvo’s confidence in the new battery design’s longevity. This warranty period matches or exceeds industry standards and addresses another common EV concern: battery degradation over time.
Implications for EV Adoption
The EX60’s combination of range and charging speed could fundamentally change the EV ownership experience. As CTO Anders Bell stated, “The EX60 is designed to be a gamechanger. With our new electric vehicle architecture, we directly address the main worries that customers have when considering a switch to a fully electric car.”
If Volvo delivers on these promises, the EX60 would eliminate the need for most owners to plan charging stops during typical daily driving or even weekend trips. The ability to recover 340 km in ten minutes makes long-distance travel more comparable to refuelling a conventional vehicle, especially as 400-kW charging infrastructure expands across major highways.
The vehicle will face competition from upcoming German rivals, including the 2027 BMW iX3 and electric Mercedes-Benz GLC, both expected to offer around 400 miles of range. However, Volvo’s early announcement and specific performance claims suggest confidence in leading the segment.
Global Launch and Availability
The EX60 will make its world premiere on January 21, 2026, with Volvo planning a livestreamed event from Stockholm. While initial launch markets haven’t been specified, the vehicle is expected to be available globally, including in North America, Europe, and key Asian markets.
Pricing remains undisclosed, but the EX60 will likely command a premium over the current XC60, reflecting its advanced technology and positioning as Volvo’s technological flagship. The company has already opened pre-sales in some markets, including Malaysia, suggesting a rapid rollout following the debut.
As the first of Volvo’s SPA3-based vehicles, the EX60 sets the template for future electric models from the brand. Its success could accelerate Volvo’s transition to becoming a fully electric car company by 2030, a goal the company reaffirmed alongside the EX60 announcement.
The EX60 represents more than just a new model—it signals Volvo’s belief that technology has finally reached a tipping point where electric vehicles can truly replace combustion engines without compromise. Whether the market agrees will become clear when the vehicle reaches customers later in 2026.
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