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Here Is How the Porsche Taycan's Unibody Is Made

Porsche’s first production electric vehicle highlights the way the German carmaker envisions the future of its products. The absence of the traditional flat-six is compensated by either a rear-motor, rear-wheel-drive, or a dual-motor, all-wheel-drive powertrain, and one of the most innovative unibody designs in the industry.
Porsche Taycan 8 photos
Photo: Porsche AG
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Unveiled as the Mission E concept at the 2015 Frankfurt Motor Show and released as Porsche’s first production EV at the same event four years later, the Taycan was an instant hit with fans and critics alike from the start, as everyone was waiting for a Tesla Model S alternative from established car manufacturers.

In order to accommodate the new technologies, the engineers at the Zuffenhausen factory needed to completely redesign the car so they chose to go with an advanced unibody style that would incorporate the large battery and support multiple motor layouts.

They chose to go with a mix of high-strength materials that would also improve rigidity for more responsive handling and power delivery, while also supplying a low center of gravity without adding too much weight.

Porsche Taycan Unibody
Photo: Porsche AG
The strut mounts, axle mounts, and the rear side members are manufactured using the highest quality die-cast aluminum, which was chosen for its high strength and lightweight properties.

The same material is used for the shock absorber mounts but they are shaped using forging to further improve the strength of the material and supply better resistance to wear.

For the construction of the front side-members, an aluminum shell was combined with seven-chamber extruded sections, which are around 3.4 kilograms (7.5 pounds) lighter than conventional ones made of steel.

The sections that form the passenger compartment, such as the A and B-pillar structures, side roof frame, and seat cross-member are made out of hot-formed steel that is especially strong and capable of sustaining high impacts while absorbing the shocks without much deformation, which exponentially increases passenger safety.

Porsche Taycan
Photo: Porsche AG
Also, manganese-boron steel is used for the manufacturing of the bulkhead cross member. The use of this alloy greatly improves strength and is especially resistant to wear. It is often used for industrial equipment.

The complete outer skin of the Taycan is made from aluminum, except for the front and rear end components. The overall content of aluminum is around 37%.

A particular challenge was developing and manufacturing the one-piece side panel that features a draw depth of 325 millimeters.

An essential part of any EV is the battery, and in order to keep a low center of gravity, the engineers decided to construct a special aluminum housing in the underbody.

The Performance Battery Plus - which is the official name of the battery – was designed as a load-carrying component and being integrated into the underbody and it is part of the safety structure of the car.

Porsche Taycan Battery
Photo: Porsche AG
Furthermore, recesses called “Foot garages” were created into the battery structure to increase rear seating comfort, legroom, and head clearance by allowing a lower seating position.

The highlight of the Taycan is the panoramic fixed glass roof that blends perfectly into its silhouette without the use of traverse bows.

It is made from thermal insulation glass, which disperses heat and will protect the interior from overheating under the hot summer sun and will retain heat in cold winters. Additionally, an intermediate layer also provides sound insulation.

Apart from the base version, the Taycan is available in 4S, Turbo, and Turbo S variants, each with increased power output. A Cross Turismo version was announced for next year, which will combine the performance of the sedan with a practical station wagon body.
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About the author: Vlad Radu
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Vlad's first car was custom coach built: an exotic he made out of wood, cardboard and a borrowed steering wheel at the age of five. Combining his previous experience in writing and car dealership years, his articles focus in depth on special cars of past and present times.
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