Tag Archives: EVs

News

Mercedes-Benz Kicks Off Pre-Series Production of the All-Electric VLE in Spain

Mercedes-Benz is officially gearing up for a new chapter in its van lineup. At its Vitoria plant in Spain, the company has begun building pre-series versions of the all-electric VLE, a model that will make its global debut in 2026. This isn’t just another van with a battery bolted in—it’s the first product developed on Mercedes’ brand-new modular, scalable Van Electric Architecture (VAN.EA), and it promises to blend the driving manners of a limousine with the space and practicality of a full-blown MPV.

A Plant Rebuilt for the Future

The Vitoria facility, which has been building vehicles since 1954, has undergone a massive modernization program to handle the new VLE. The factory’s 5,000 employees were retrained on new digital tools, IT systems, and manufacturing techniques. A new body shop and fully flexible paint line have been added, and the assembly hall was overhauled—all without stopping the current production of the Vito, eVito, and V-Class.

Mercedes is touting the Vitoria plant as a benchmark for sustainable production. Since 2013, all purchased electricity has been sourced from renewables, and the factory now generates its own green power via solar panels. Geothermal energy heats the buildings, while waste heat from the paint shop is also reused. As part of the brand’s larger push, production across Mercedes-Benz Vans is net carbon-neutral.

Digital-First Manufacturing

For the VLE program, Mercedes leaned heavily on digital methods. The entire plant was virtually recreated as a “digital twin” before physical construction, enabling engineers to fine-tune processes with AI-driven simulations. The result? Faster ramp-up, fewer errors, and greater efficiency. And when series production begins in 2026, the VLE will debut the Mercedes-Benz Operating System (MB.OS) in a van for the first time.

What to Expect from the VLE

The VLE will be offered in a wide range of configurations—from eight-seat family haulers to plush executive shuttles. Mercedes promises sedan-like ride and handling paired with versatile space management. Early prototypes have already proven their mettle:

  • Aerodynamics: Record-breaking results in the wind tunnel.
  • Real-World Range: A Stuttgart-to-Rome road trip required only two 15-minute charging stops.
  • Performance: High-speed agility at Nardò’s test track in southern Italy.
  • Durability: Arctic Circle testing showed resilience in extreme cold and snow.

And while the first VLE models will be electric-only, the new platform is designed with flexibility in mind—meaning combustion versions are also in the pipeline.

Why It Matters

Mercedes is betting big on electrification in the van segment, and the VLE is the spearhead. Unlike today’s eVito or EQV, which are adaptations of combustion platforms, the VLE is electric from the ground up. That means better packaging, improved efficiency, and a more competitive stance against newcomers in the EV people-mover and light-commercial market.

Looking Ahead

“The new VLE is the first vehicle of our new, modular and highly flexible van architecture. In record time we have brought the VLE from the initial concept considerations to production maturity,” said Thomas Klein, Head of Mercedes-Benz Vans.

Vitoria’s plant boss, Bernd Krottmayer, was even more direct: “We are ready to build the future of Mercedes-Benz Vans.”

When the production-spec VLE finally breaks cover in 2026, it won’t just mark the launch of a new model. It will represent the start of a new generation of Mercedes vans—digitally engineered, sustainably built, and designed to drive like nothing else in the segment.

Source: Mercedes-Benz

NEW CARS

Cayenne Electric Takes Shape: Virtual Testing Meets Desert Heat

When Porsche pulls the wraps off the Cayenne Electric later this year, it won’t just be unveiling its first all-electric SUV—it’ll be showing off a revolution in how cars are developed. For the first time, the German marque skipped the usual stage of building dozens of mule prototypes and went straight from digital simulations to pre-series production. That’s right: the Cayenne Electric was born in pixels before it ever touched pavement.

“Construction-stage testing with one-off prototypes was no longer necessary,” explains Dr. Michael Steiner, Porsche’s R&D chief. “Roughly 120 test vehicles were largely replaced by digital equivalents.” In other words, engineers started flogging the Cayenne long before there was a Cayenne to flog.

Virtual Nürburgring Laps, Real Stress Tests

The secret is simulation. Porsche’s Weissach engineers digitized routes from city commutes to the Nürburgring Nordschleife, then ran virtual Cayennes across them. With modern computing power and decades of test data, the simulations were accurate enough to predict how the SUV would handle braking, cornering, and power delivery.

A new “composite test bench” made the leap from virtual to physical. This setup combines four electric motors capable of mimicking real-world driving resistance, from rough asphalt to tire slip, while also testing the battery, charging system, and thermal management under load. “The machines are so sophisticated that we can even replicate different asphalt surfaces,” says engineer Marcus Junige.

On the Nordschleife, the Cayenne Electric had to deliver full power, lap after simulated lap, without faltering. Porsche’s thermal management system—its most advanced yet—proved capable of keeping the battery cool enough for repeat punishment. Test-bench results lined up so closely with digital data that almost no correction was needed.

Where Humans Still Matter

But Porsche is quick to remind us that no matter how sharp the software, the final polish is human. “In reality, only humans can perform the finishing touches,” says Sascha Niesen, who leads overall vehicle testing in Weissach. Porsche’s development drivers are still irreplaceable when it comes to tuning the delicate balance of dynamics, control strategies, and feedback that define a Porsche.

That means testing in the real world, too. The Cayenne Electric has endured traffic jams, desert highways, alpine passes, and Scandinavian winters. At 50°C in Death Valley, Porsche stressed the cooling system. At -35°C in Sweden, engineers focused on cold starts, traction, and regenerative braking. And in every case, the SUV had to arrive ready for fast charging—whether after a Nürburgring lap or a snowbound commute.

Faster, Leaner, Greener Development

The hybrid approach—virtual first, real-world second—has slashed Porsche’s development time by about 20 percent while cutting down material waste. It also means endurance testing happens sooner: pre-production Cayennes have already racked up 150,000 kilometers in mere months, simulating years of owner abuse in city streets, highways, and country roads.

The result? A vehicle that blends Porsche’s old-school obsession with precision driving dynamics and its new-school commitment to sustainability.

When the Cayenne Electric makes its debut later this year, it won’t just mark a new chapter for Porsche’s biggest seller—it’ll stand as proof that the future of testing is as digital as it is analog.

Source: Porsche

News

Stellantis Gives Old EV Batteries a New Mission: Powering Mobility for All

Stellantis is proving that an electric vehicle battery’s life doesn’t end when the car does. Through its circular economy arm, SUSTAINera, the automaker is repurposing high-voltage packs for “second-life” duty—and one of the most compelling examples yet isn’t powering a car, but helping people move in an entirely different way.

Meet AVATHOR ONE, an electric mobility device designed for wheelchair users and people with reduced mobility. Instead of relying on freshly built batteries, AVATHOR ONE runs on modules reclaimed from Stellantis EVs. The packs are collected in Turin, tested, and re-engineered by INTENT S.r.l., a local system integrator. The result: compact 1.4- or 2.8-kWh units that drive the device’s electric heart, backed by a modern battery management system.

Think of it as recycling meets inclusivity. “A second life for batteries, a new freedom of mobility for people,” is more than a slogan here—it’s a practical example of how automakers can merge sustainability and social responsibility without compromising technology.

The project is a local ecosystem done right. Stellantis supplies the used EV batteries. INTENT breaks down, repacks, and reintegrates them. Avathor, a Turin-based startup, builds the device itself, while legendary design house Italdesign shapes the product from its 2019 concept (the WheeM-i) into the market-ready AVATHOR ONE. The collaboration officially launched in April and has already been showcased globally—first at Expo 2025 Osaka, and next at the upcoming Salone Auto Torino.

And AVATHOR ONE isn’t just a feel-good story. It’s part of a much bigger Stellantis strategy to wring maximum value out of its EV batteries. Beyond mobility aids, SUSTAINera has partnered with utilities and battery integrators on large-scale energy storage, including ENEL X’s PIONEER project at Rome Fiumicino Airport. That installation—the largest of its kind in Italy—stores renewable energy, cuts CO₂ emissions by an estimated 16,000 tons over a decade, and shows that repurposed car batteries can scale well beyond niche applications.

The goal is nothing less than a 360-degree approach to EV battery life: Reuse, Repurpose, Remanufacture, and Recycle. In other words, keep these high-voltage packs working as long as possible before they hit the shredder.

For Stellantis, that strategy is both a business model and a statement. The company has seen “second-life” battery demand surge over the last three years, and it’s investing heavily to keep the momentum. If AVATHOR ONE is any indication, the payoff won’t just be measured in carbon savings—but in freedom of movement for people who need it most.

Source: Stellantis