Energy innovation takes shape here: the birthplace of future electricity.

Energy innovation takes shape here: the birthplace of future electricity.

A 4-minute read

In the heart of Saxony, Germany—the region where the German reunification movement flourished—lies a distinctive car factory. Unlike typical automobile plants, this facility in Zwickau, owned by the Volkswagen Group, boasts an immense number of robots. This is where electric vehicles enter Volkswagen's Third Era, following the iconic Beetle and the Golf, which rescued the Wolfsburg-based company from bankruptcy in 1974 and propelled it to global dominance. However, the current challenge is overcoming the production halt resulting from the shutdown emergency.

The group, having navigated the Dieselgate scandal, is tackling the energy transition with a €79 billion investment plan for all its brands. The Volkswagen brand's revolution revolves around the new "ID." models, born as fully electric vehicles. Unlike converted internal combustion engine vehicles, these cars are constructed on a purpose-built platform, the MEB (Modular Electric Drive Matrix), designed to foster the creation of various car types with different styles and brand identities while leveraging common modular bases.

The MEB platform, a true engineering masterstroke, follows the success of the MQB architecture. It allows for production optimization, echoing the ideals of Industry 4.0, and can be replicated worldwide. This versatile platform has fewer parts and requires less labor than traditional cars, making electric vehicles more viable.

Currently, Zwickau produces the ID.3, the first MEB-based car and a zero-emission five-door compact sedan similar in size to the Golf. Priced around €30,000, the ID.3 aims to popularize electric vehicles. Should coronavirus-related disruptions cease, a second model, the ID.4, an SUV, will follow. The Zwickau plant, historically a trading town and a coal mining center, has invested more than €40 billion in electrification and has been redesigned for electric vehicle production.

The production process in Zwickau features nearly 1,700 robots, autonomous transport systems, and fully automated production processes. Robots also assemble the car bodies using welding techniques that prioritize energy efficiency over speed. The assembly of parts like dashboards or roofs is performed by hand.

The revolution in electric vehicles marches on, marking a significant departure from the sooty, intimidating two-stroke engines of the Beetles. This transformation embodies robots, the future, and the fusion of machines and man. Modernization of Zwickau's facilities began in 2018, and production of the ID.3 commenced on November 4, 2019. In full capacity, the factory can produce up to 330,000 units annually, catering to six models based on the MEB platform for three brands (Volkswagen, Audi, and Seat) and Ford, starting from 2023.

The lines in Zwickau are carbon neutral, now silent and deserted. The production process is highly automated, streamlining efficiency and reducing labor. The MEB platform's modular design and component sharing optimize production, play a crucial role in cost reduction, and contribute to industry collaboration efforts. This technology is instrumental in Volkswagen's commitment to making electric vehicles more accessible worldwide.

1. Despite challenges caused by the shutdown, the Volkswagen Group is investing €79 billion to transition its entire manufacturing industry towards electric vehicles across all its brands.
2. The MEB (Modular Electric Drive Matrix) platform, a strategic engineering masterpiece, not only solidifies Volkswagen's revolution with the new "ID." models but also brands like Audi and Seat, by fostering the production of various car types.
3. The Zwickau factory, equipped with nearly 1,700 robots, autonomous transport systems, and fully automated production processes, is part of the automotive technology evolution, transforming the traditional manufacturing industry.
4. Finance, being a crucial aspect, this massive investment in the electric vehicle sector will make environmentally friendly transportation more affordable for everyday lifestyles, setting a trend for the automotive industry and the global adoption of electric-vehicles.
5. The automation of the production process in Zwickau's facilities not only ensures efficiency but also enables the factory to produce up to 330,000 units annually, catering to six electric-vehicle models for three brands – Volkswagen, Audi, Seat, and Ford – by 2023.

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