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Design and cost optimization, automotive companies in the direction of electric vehicle platforms

In recent times, many have come across news about accidents, particularly those involving Uber and the Tesla Model X. When it comes to the development of technology, it's easy to spot the weaknesses of electric vehicles (EVs) and autonomous driving systems—though we might also say these challenges are still in their early stages. However, as with any technological advancement, progress is inevitable. It follows the principle of "survival of the fittest," where problems are addressed one by one as they arise. Today, I came across an inspiring article from McKinsey titled *"What a teardown of the latest electric vehicles reveals about the future of mass-market EVs."* The piece highlights how automakers have made significant strides in optimizing design and reducing costs. Companies are achieving partial breakthroughs in their vehicle configurations, whether through improved design efficiency or lower manufacturing costs. These efforts are gradually bringing down the overall cost of EVs, making them more accessible to a broader range of consumers. As shown in Figure 1, once a benchmark EV can achieve an average range of over 300 kilometers (or 185 miles), OEMs can begin to focus on the low-price segment while still maintaining sufficient driving range. This suggests that the long-awaited mass-market electric vehicle—specifically a mid-sized car designed for the average consumer—may soon become a reality. Electric vehicle platforms are also evolving. Although they require higher upfront investment in terms of engineering and tooling, new platforms offer superior performance across the board. By designing the vehicle architecture from the ground up for electric use, manufacturers eliminate the need for traditional engine components, leading to greater flexibility and fewer compromises at the engineering level. Thanks to these new platforms, energy losses are being reduced, especially in the vehicle’s structure and battery system. This allows for larger battery packs, which in turn increases the vehicle's range. On average, the battery pack volume has increased by 25% compared to previous models. Additionally, the body structure can be designed around the battery, without needing to integrate into existing frameworks. The engineering freedom offered by these platforms often means that larger batteries can be installed, along with other benefits such as higher discharge power and faster charging speeds. With rapid advancements in battery technology, the range limitations of EVs continue to shrink, pushing the industry closer to the early stage of fuel-powered vehicles in the mass market. Another key trend is the integration of the electric powertrain. From a disassembly perspective, the powertrain is moving toward a more integrated design, with many power electronics components physically combined into fewer modules. While there's no universal approach to integration, the overall trend shows that core components and wiring are becoming simpler and more efficient. Looking ahead, the next big focus will be on the efficient integration of thermal management systems, aiming to improve energy control and efficiency. This is crucial for the continued evolution of electric vehicles. A2mac1 recently took apart a Tesla Model 3, and I hope to see more detailed disassembly reports in the future. From what’s visible, the layout of electric vehicles is becoming much simpler, and the new platform doesn’t take up more space than traditional ones—this is a major advantage. To enhance their appeal, electric vehicles are increasingly integrating smart features and advanced cockpit electronics. At this stage, EVs need more than just range and charging speed—they must offer compelling tech features to change public perception and stand out in the market. Profitability for pure electric vehicles is heavily dependent on cost. For now, subsidies help some models reach acceptable profit margins, but as subsidies decrease, strict cost management will become even more critical. The challenge lies in offering attractive pricing without sacrificing profitability. Cost control and continuous reduction will be the key differentiators in the competitive EV market. In summary, the road to full electrification is challenging, but it's a necessary path. It lays the foundation for autonomous driving and automotive electronics. First, we need reliable vehicles before we can add all the smart features. The journey is tough, but it's essential for the future of mobility.

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