Volvo has announced that its upcoming all-electric EX60 SUV will be launched in January 2026. The model will succeed the XC60 and feature structural batteries, rear mega-casting, and a software-focused architecture.
Structural Updates
The EX60 will be Volvo’s first vehicle to use a single-piece aluminium rear section, replacing multiple welded components. This Tesla-style “mega-casting” reduces complexity, cuts production time, and improves energy absorption in rear impacts. According to Volvo engineers, the process allows for tighter tolerances and structural efficiency. The company claims this approach lowers body weight by up to 15%.
Volvo will also use structural batteries for the first time on the EX60. These battery packs form part of the vehicle’s floor, helping with rigidity and better packaging. This design enables lower ride heights without compromising on either crash safety or cabin space.
Platform & Software Integration
The EX60 will share its platform, the new SPA3 architecture, with the larger EX90. The platform is modular and scalable, allowing it to support a range of vehicle sizes. The new platform also centralises software control into a “superset” electronic control unit (ECU), enabling real-time over-the-air updates for critical software controlling drive systems, safety features and the infotainment system.
SPA3 will reduce reliance on domain-specific ECUs. Manufacturing will become more efficient by consolidating parts and fewer mechanical interfaces between components.
New Seatbelt Design
The EX60 will debut a new “multi-adaptive” seatbelt system designed to work with Volvo’s evolving crash sensor suite. The mechanism adapts belt tension in real-time based on occupant position and predicted crash type. The brand has confirmed this feature is exclusive to the EX60 at launch, with future rollouts depending on hardware integration across the range.
The vehicle will also continue Volvo’s use of camera and radar-based ADAS, though it isn’t confirmed whether LiDAR will be available on this model.
Conclusion
The EX60 represents the integration of structural, electronic, and software systems into a unified EV platform. Unlike previous models, the focus here is on production efficiency and foundational engineering over visible design changes. Final technical specifications and pricing will determine whether the EX60 competes effectively in a segment already populated by many competent rivals such as the iX3, the EQC, the Tesla Model X, and many undercutting products from BYD.
