Case Study
Get Ready for the Future of Automotive
Navigate the transition to sustainable mobility with flexible, high-performance automation solutions for battery assembly, e-motor production, and megacasting. As the automotive industry shifts from ICE to Electric and Hybrid powertrains, production lines must evolve. Discover how ABB’s specialized robotics solutions optimize every stage of EV manufacturing, from battery cells to the final paint shop.
- Topic
- Business Solutions
- Published
- 22 Jan 2026
The automotive industry is undergoing its most radical transformation in over a century. The transition to Electric Vehicles (EV) and Hybrids (PHEV) requires a fundamental shift in manufacturing philosophy, moving away from rigid lines toward flexible, automated cells.
This comprehensive guide explores ABB’s 50 years of automotive expertise applied to the modern EV landscape. Learn how to master the complexities of battery tray manufacturing, high-precision e-motor assembly, and the emerging challenges of mega casting machining. By integrating advanced robotics, manufacturers can achieve the high throughput and sustainability required by global regulations while maintaining the agility to pivot between vehicle models at record speed.
Key Highlights:
EV-Specific Expertise: Dedicated solutions for the unique requirements of Electric Vehicle and Hybrid production.
Mastering Megacasting: High-accuracy robotic machining solutions for large-scale aluminum structural components.
Precision E-Motor Assembly: Automated processes for stator and rotor production, ensuring high-quality electrical powertrain output.
Complete Battery Lifecycle: Solutions spanning from battery tray welding and sealing to final pack assembly and testing.
Flexible Manufacturing Cells: Modular automation that allows for rapid reconfiguration between different vehicle models.
Sustainability at Scale: "Leaner and cleaner" operations designed to reduce energy consumption and material waste.
Enhanced Safety & Collaboration: Advanced software and sensors that allow robots to work safely alongside human technicians.
Optimized Paint Shop Solutions: High-efficiency robotic painting and sealing tailored for new EV chassis designs.
Chassis Innovation: Precision manufacturing for modern chassis components, ensuring structural integrity for heavy battery loads.