Volvo Reportedly Builds EX60 at One-Tenth of Plan, Delaying US Supply

About 200 vehicles per week: That is the reported production rate for Volvo’s new EX60 electric SUV at its upgraded Torslanda plant in Sweden. The original plan was approximately 2,000 per week, leaving output at roughly one-tenth of the intended pace and US dealers with only limited inventory.

Early EX60s have reached the United States, but substantial supply reportedly will not arrive until well into 2027. Volvo spokesperson Jacquelyn Johnson said near-term availability would remain limited and that many vehicles allocated to US retailers are expected in early 2027. Dealers have reportedly been told to expect restricted supply through the first half of the year, with more meaningful availability in the second half.

The gap is large enough to affect Volvo’s initial sales plan. The intended production rate was designed to support a first-year US goal of 7,000 EX60s, according to dealer guidance cited by Automotive News. At 200 vehicles a week, worldwide production would amount to about 10,400 units over a full year if the rate remained unchanged before allocating vehicles among the United States and other markets.

Battery integration and motor output are reported constraints

Industry reporting attributes the slow ramp to difficulties integrating the high-voltage battery pack with the vehicle body and to electric-motor production at Torslanda. Volvo has not released a detailed technical root cause, so it remains unclear which process steps are limiting throughput, how much each constraint contributes or when the plant can reach its planned rate.

In vehicle manufacturing, nominal line capacity does not by itself determine output. Battery installation, electrical connection, sealing, dimensional verification, software commissioning and end of line testing must all remain synchronized with body and powertrain supply. A bottleneck at one station can restrict the entire factory even when other sections have unused capacity. Motor production presents a similar systems problem: Final assembly cannot compensate for missing propulsion units simply by running faster.

No reported information connects the slowdown to a safety or quality defect in the EX60. The issue described so far is one of production integration and capacity during a new-model ramp.

A new body architecture raises the integration stakes

The EX60 is also Volvo’s first model built around its new megacasting architecture. At Torslanda, one large aluminum casting replaces dozens of stamped and welded steel parts in the rear floor structure. A detailed look inside the manufacturing process describes a 43-kilogram finished casting produced on a two-minute cycle, with trimmed aluminum returned to the plant’s melting system.

That approach can reduce part count, welding operations, internal logistics and intermediate inventory. It also concentrates more manufacturing responsibility in a smaller number of major processes. Large structural castings require control of metal flow, temperature, porosity, cooling and final geometry, while their interfaces with the battery system must meet dimensional requirements at production speed.

The available reporting does not identify megacasting as the cause of the EX60 slowdown. Its relevance is architectural: Volvo is simultaneously introducing a new electric SUV, a highly integrated battery and body arrangement and its first production application of a large single-piece floor casting. Each system must reach stable output together before the factory can sustain its planned rate.

Volvo’s own US EX60 page reflects a staged arrival. It lists fall 2026 customer deliveries for the P10 all-wheel-drive version, while the P6 and P12 versions are expected in 2027. Those dates describe planned customer availability, but the reported factory rate will determine how many vehicles dealers can actually offer within those windows.

The timing carries added weight because the EX60 is central to Volvo’s stated objective of reaching 200,000 annual US retail sales by 2030. The smaller EX40 remains available as a 2026 model but is scheduled to leave the US market after its current generation, increasing the importance of a successful EX60 ramp.

For US buyers, the immediate consequence is straightforward: A vehicle presented as a major new entry in Volvo’s electric lineup may technically be on sale while remaining difficult to find. The next meaningful milestone is not another specification announcement, but evidence that Torslanda can move materially beyond 200 EX60s per week and sustain that increase long enough to supply American dealers in the second half of 2027.

By Thomas Caldwell — AMI’s senior editor for mechanical and mobility engineering, covering vehicle electronics, systems integration, electrification, chassis systems, propulsion, and safety policy.