WEVC (Watt Electric Vehicle Co.) today revealed a lightweight, high-performance architecture for next-generation sports cars and other small-series EVs. The new architecture from the pioneer in the design, engineering, and manufacture of low- to medium-volume EVs, both under its brand and for third parties, enables low-volume manufacturers to make the zero-emissions transition quickly and cost-effective via an “off-the-shelf” EV platform that complies with the latest safety standards.

The passenger vehicle platform is based around the company’s PACES (Passenger And Commercial EV Skateboard) architecture that also underpins the company’s UK-designed and -engineered eCV1 electric light commercial vehicle for fleet customers with the start of production next year.

“Electrification is a major challenge for small series manufacturers,” said Neil Yates, Founder and CEO of WEVC. “With low sales volumes, it is difficult for these businesses—whether start-ups or established brands – to invest in their own new EV technology and develop it in-house. WEVC’s PACES architecture is a highly sophisticated, lightweight off-the-shelf flexible platform that is not only cost-effective but has been designed to meet ISO and European Small Series Type Approval crash standards.”

The bonded aluminum platform is designed to be flexible, scalable, lightweight, and cost-effective for low-volume manufacture. It can be applied to almost any size or shape of passenger EV in FWD, RWD, and AWD layouts.

“This cutting-edge, modular platform has been specifically designed for low-volume manufacture, a blank sheet of paper providing the best possible structural and dynamic starting point for almost any future high-performance EV, whether a featherweight rear-drive roadster, luxurious coupe, or off-road buggy,” added Yates. “It also comes fully supported by our leading UK-based EV technology supply chain and, of course, WEVC’s in-house design, engineering, and manufacturing capabilities.”

The company says that, while large-volume aluminum skateboard concepts use custom, complex, and expensive corner castings, its PACES is composed of lightweight extrusions—flat, laser-cut pieces—interlocked and bonded together. For the innovation it calls FlexTech, it can form a chassis that is low cost, extremely rigid, and accurate, delivered to within 1 mm (0.04 in) of variability across the whole platform.

As a result, it requires little upfront investment in expensive tooling or post-assembly machining, further cutting manufacturing costs. Its “module-to-chassis” system means batteries are integrated into the primary structure rather than having a separate battery pack, optimizing stiffness and minimizing weight.

In November, WEVC announced that it is working with Norway’s Hydro to explore using certified recycled and low-carbon aluminum to produce extrusions for its eCV1. Hydro’s low-carbon aluminum has a CO2 footprint of just 4.0 kg (8.8 lb), vs. a world average of 16.7 kg (36.8 lb), of CO2 per metric ton, in part thanks to the renewable energy used in the production process.

The two companies will also evaluate using recycled aluminum with a lower carbon footprint in UK-manufactured automotive structures for the first time.

Overall, WEVC aims to cut embedded carbon in the production of its eCV1 by significantly more than 50% compared to other electric LCVs. Leveraging the combination of WEVC’s Flex-Tech architecture and Hydro’s new low CO2 and recycled aluminum products, WEVC expects to be the first commercial vehicle manufacturer to significantly reduce CO2 emissions in manufacture, a cornerstone in delivering its sustainability objectives.

“We are discussing with WEVC how we can work together to build a closed-loop recycling process for the eCV1 at the eventual end of the vehicle’s life,” said Paul Warton, EVP of Hydro Extrusions. “Having the vehicle manufacturer directly returning pure Hydro aluminum products, which are a known quantity in terms of quality and type of alloy, makes reprocessing easier and reduces the carbon footprint of the resulting aluminum products drastically.”

The eCV1 van combines low life-cycle emissions, light curb weight, efficient energy use, and large payload capabilities, the lightweight aluminum playing a pivotal role in all those attributes. The first product from WEVC is designed for the production of 5000 vehicles per year, but its base enables a range of electric commercial vehicle designs, facilitating mission-specific models that meet customer fleet requirements.

The eCV1 prototype has a curb weight starting at just 1750 kg (3860 lb) and is said to deliver class-leading payload and range in the 3.5- and 4.25-t segments. Real-world testing started in 2023 as the engineering program builds towards full design verification/test sign-off and the start of production in 2025.