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The 2025 Polestar 3 isn’t just another luxury EV. It’s a meticulously engineered machine that prioritizes structural integrity, ride quality, and brand identity. In this underbody review, the Munro team go beneath the skin of the all-electric SUV. They reveal the complex architecture, high-end materials, and costly engineering decisions that make the Polestar 3 stand out.
Forged to Impress: Wheels and Suspension
Right out of the gate, the Polestar 3 makes a statement with its wheels. These aren’t your average aluminum cast wheels—they’re forged, polished using a tumbling process, and coated with multiple layers of clear coat. Even the lug covers are forged aluminum, not injection-molded plastic, with costs pushing upward of $100 just for finishing. This attention to detail sets the tone for the rest of the vehicle.
The suspension features an all-forged design—double wishbones up front with forged upper and lower control arms, forged knuckles, and additional brackets for optimal dynamic control. Large Brembo brakes support the substantial weight of the SUV, which hovers around 6,000 lbs GVWR. Polestar is clearly banking on performance and premium design to justify the $90,000+ price tag.
Aluminum Everywhere: A Material Story
Beneath the Polestar 3 is a symphony of aluminum in every form—castings, extrusions, and forgings dominate the underbody layout. From front to rear, the structure uses welded extruded subframes, friction stir welded floor sections, and massive die castings for battery module integration. The battery itself is a 111 kWh pack, tucked securely between the axles, but its efficiency leaves room for debate. With a rated range of 280 miles, it trails behind Tesla’s Model X, which could theoretically extract over 350 miles from the same capacity.
Crash Safety as a Structural Priority
Safety remains a central theme, in keeping with Polestar’s Volvo heritage. The front-end architecture relies on wide, splayed aluminum rails. It also incorporates layered stampings to distribute crash energy effectively. Together, these elements help manage impact forces across a variety of crash scenarios. This includes full frontal collisions, moderate overlaps, and small overlap impacts. And unlike parasitic sorb structures seen in other EVs, Polestar’s system puts every component to work in real-world driving, not just in the event of a collision.
Diagonal braces, steel tubes, extrusions, and stanchions all integrate to form a contiguous load path from the vehicle’s threshold to its motor bay and cradle structure. This is true lean design at work—every gram of material is doing multiple jobs.
Powertrain Packaging and System Integration
The coaxial electric drive module (EDM) used in the Polestar 3 minimizes packaging space by aligning the rotor-stator and shaft concentrically. This helps in maximizing interior and battery packaging while still allowing robust mounting and crash protection structures.
The front cradle is built from extruded aluminum, while the rear cradle—supporting a sophisticated integral link suspension—relies on sand castings. This mixed-material strategy likely reflects decisions driven by manufacturing scalability. Extrusions are better suited for low-volume production due to their flexibility. In contrast, castings offer greater cost efficiency when produced at scale.
There are signs of cost-conscious engineering too, such as directly threaded castings that eliminate the need for nuts on some suspension mounts. While this improves packaging and reduces part counts, it also raises concerns for serviceability if threads are damaged during maintenance.
Air Suspension Complexity and Benefits
One of the standout systems in the Polestar 3 is its dual-chamber air suspension setup. This isn’t just for comfort—it’s about performance and versatility. Drivers can expect adjustable ride height and spring rates, with benefits for aerodynamics, off-road clearance, and loading convenience.
However, the added performance comes with durability concerns. Air suspensions, especially in premium brands, have historically had a reputation for long-term reliability issues. And while modern systems have improved, the complexity—complete with pumps, compressors, and EPDM lines—adds to both the vehicle’s cost and its potential points of failure.
Thermal and Electrical Management
Thermal routing in the Polestar 3 is notably elaborate. Coolant lines, brake lines, and air suspension hoses run neatly along both sides of the vehicle. The underbody also includes strategically placed extrusions to protect the battery pack from side impacts. This is another nod to Volvo’s safety-first philosophy.
The front underbody design features tight clearances and thoughtful shielding for high-voltage components. An injection-molded or thermoformed liner protects the front wheel wells, while the rear uses softer PET material for improved noise, vibration, and harshness (NVH) control.
Casting Strategy: Low Volume Meets High Complexity
Castings are used extensively in the rear—especially around the EDU (electric drive unit) cradle and suspension components. In contrast to high-pressure die castings used by competitors like Tesla, the Polestar 3 seems to favor sand casting, a more economical choice for lower-volume parts. Even the rear suspension arms are hollow cast, a possible aerodynamic consideration as well as a strength optimization.
The rear EDU also features dual pumps—likely for a hydraulic disconnect system that turns off the rear motor under low load to reduce drag. The reasoning behind the two-pump layout remains unclear, but it underscores the intricate engineering packed into the drivetrain.
Designing for Premium Brand Identity
Although Polestar is technically a new player, it benefits from the legacy of Volvo and the manufacturing might of Geely. The vehicle doesn’t feel like a startup experiment—it feels polished. From pedestrian safety features like clad speakers to mass dampers and quality welds, the Polestar 3 exudes a level of maturity in its engineering.
Still, some features may signal platform sharing or cost-cutting, like the possible reuse of stamping components or large cast nodes that might only exist in certain variants. Overall, the vehicle strikes a balance between innovative design and pragmatic manufacturing.
Final Thoughts: Worth the Cost?
The Polestar 3 isn’t the most efficient EV in its class, nor is it the cheapest. But when it comes to engineering rigor, material choice, and safety-first design, it delivers on its premium promise. It feels like a Volvo beneath the skin—but with a sharper, more electrified edge.
For automotive engineers, EV investors, or enthusiasts keen on structural analysis and system integration, the Polestar 3 offers a compelling case study in how legacy brands adapt to electrification without compromising on core values.
Want deeper insights into Polestar 3 underbody engineering?
Watch the full teardown on Munro Live or contact our team to explore how premium EV platforms like this are redefining structural performance and safety. Or reach out for consulting on lean design and cost reduction strategies. Let’s build better together.