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When it comes to pushing the boundaries of solar electric vehicle design, few companies capture imagination like Aptera Motors. In a recent factory tour, Sandy Munro of Munro & Associates was given a deep look into how Aptera is redefining what’s possible with lightweight structures, solar efficiency, and manufacturing innovation. This tour, filled with engineering insights and cost-conscious design strategies, highlights how every journey might truly be powered by the sun.
Aerodynamics and the Birth of Aptera
At the heart of Aptera’s mission lies a deceptively simple challenge: how to travel the farthest using the least amount of energy. Co-CEOs Chris Anthony and Steve Fambro began their journey with a relentless focus on aerodynamic efficiency. Most vehicles expend 60–70% of their energy fighting air resistance. Aptera flips the equation. Through computational modeling and reference to historic aerodynamic texts, they shaped a body so efficient that it can potentially travel up to 40 miles per day on solar power alone—without ever needing to plug in.
This leap was made possible with high-efficiency solar cells from Maxeon. Once the team calculated how much power a small array could generate, they made a bold decision: cover the entire vehicle in solar cells. That decision became the cornerstone of Aptera’s design philosophy.
Solar Panels and Energy Autonomy
One of the tour’s highlights was the discussion of Aptera’s proprietary solar integration. Unlike conventional solar add-ons, Aptera’s panels are curved, vehicle-integrated modules with a thin, durable glass coating. Their real breakthrough lies in preventing micro-cracking—a degradation that occurs with flex and vibration in typical solar applications. Their encapsulation methods, polymer stacks, and glass overlays strike a rare balance between flexibility, strength, and scratch resistance.
Aptera has already proven this technology outside the automotive sector. In a major deployment at airports, their solar-powered electric vehicles eliminated the need for frequent charging, thereby cutting infrastructure costs and operational delays. As a result, this pivot hints at vast commercial opportunities beyond personal transportation—ranging from industrial ground fleets to grid-independent logistics.
Lean Manufacturing with Munro’s Touch
Lean manufacturing is central to Aptera’s strategy. And, notably, the Munro team played a direct role in its development. With help from Munro & Associates, Aptera’s production process was mapped into 12 stations with a 12-minute takt time. Consequently, this setup enables 40 vehicles per shift and up to 80 daily with dual shifts. In turn, that equates to an impressive 20,000-vehicle annual throughput. And all of it achieved without massive automation investments.
Each station builds on the last, starting with the heaviest element—the battery pack—and culminating in final quality checks. This tightly engineered flow is supported by Aptera’s modular component design and their preference for human-handled assemblies. Most parts are light enough to position without robotic aid, which reduces capital costs and boosts flexibility.
Lightweight Structure: SMC and Carbon Fiber
Another standout feature is Aptera’s use of carbon fiber and Sheet Molding Compound (SMC). The car’s primary structure weighs only 200 pounds—lighter than even the BMW i3’s carbon chassis. By leveraging the world’s largest carbon SMC parts and innovative mold designs sourced from Italian firms like CPC and Energy, Aptera achieves aircraft-grade rigidity at automotive costs.
What makes this structure special is its combination of accuracy and durability. In particular, components key into each other like Legos, minimizing misalignment. With SMC, there’s no need for draft angles, giving designers greater aesthetic and functional freedom. These parts come out of molds ready for wrapping—no sanding or surfacing required. This alone streamlines finishing and improves consistency.
Function-Driven Aesthetics and Storage
Beyond engineering, Aptera shines in design practicality. For example, the interior has been enlarged in the latest Gamma version to improve comfort and storage. Moreover, from the elongated hatch to hidden camera-based side mirrors, the form always follows function. The vehicle offers 1,000 liters of cargo space—enough to hold surfboards, skis, or even a tent system for camping. Their focus on maximizing interior volume while maintaining low drag continues to set Aptera apart.
From a vehicle registration standpoint, Aptera qualifies as a motorcycle in most regions. This clever classification avoids some stringent automotive regulations while enabling ultralight construction and cost savings.
Component Optimization and Teardown Lessons
Aptera’s iterative design philosophy mirrors the teardown culture at Munro & Associates. Every part—from suspension arms to door structures—has been analyzed for cost, weight, and manufacturability. For example:
- Solar hatch: Glass-covered, composite-backed, and extremely light—under 40 lbs.
- Wheel pants and hubs: Designed for minimal aero drag with future die-casting in mind.
- Suspension: Designed to emulate 4-wheel dynamics, reducing the quirks of 3-wheel platforms.
- Body panels: Fiber-reinforced where needed; fiberglass shells elsewhere for cost and simplicity.
Sandy Munro praised the precision and predictability of Aptera’s builds, noting that everything “looked like the CAD” and assembled without surprises—an extremely rare feat for a startup.
Cost Efficiency and Capital Discipline
Perhaps the most impressive detail? Aptera has reached this production-intent prototype phase with only $100 million invested. Traditional OEMs often spend five to six times that amount just to get to tooling and validation. The Aptera team achieved this through smart partnerships, lean design, and refusing to overbuild.
The company is currently raising an additional $60 million through a convertible note to fund final tooling and validation, with plans to expand crowdfunding access to smaller investors in the near future. Their stated mission? Deliver one million Apteras by 2033.
Strategic Focus: Control and Mission
Despite interest from Chinese and global investors, Aptera has remained steadfast about maintaining control. Their goal isn’t to flip a product—it’s to revolutionize personal mobility. They’re seeking strategic partners who align with their core values: efficiency, sustainability, and affordability.
Final Thoughts: A Bold Future for Solar EVs
The Aptera factory tour wasn’t just a showcase of engineering—it was a case study in focused innovation. From its ultra-light SMC body to the solar-panel integration and right-sized manufacturing philosophy, Aptera challenges assumptions about what an EV can be.
By staying lean, smart, and bold, Aptera proves that solar electric vehicle design isn’t just viable—it’s desirable. The journey is far from over, but it’s already inspiring.
Discover More With Munro
Curious how the team at Munro can help you achieve the same level of cost-effective innovation? Explore more teardown videos on Munro Live. Or connect with Munro & Associates to accelerate your next product and dive deeper into EV innovation, cost analysis, and lean design.