The Polestar 5 will be built atop a 'bespoke' bonded aluminum platform

Andrew Tarantola

Because welding aluminum generally halves its yield strength, you end up having to use double the amount of material to achieve the same performance — which defeats the whole purpose of using the lightweight metal in the first place. Bonding aluminum parts together (ie affixing them with screws and adhesive), on the other hand, cuts down on the materials needed but at the cost of extended production times.

We were able to bake in the structural stiffness targets we need to meet our dynamic performance aspirations at the beginning of the project," Swifts said, explaining the benefits of a unibody construction process.

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