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The Chevy Equinox EV offers a fresh look at General Motors’ BEV3 architecture. In a recent walkthrough, Munro & Associates’ expert engineers examined the underbody in detail. Their focus—taking a close look at the chassis, cradle, suspension, structural design, and small overlap rigid barrier (SORB) strategies. This comprehensive underbody analysis sheds light on GM’s design direction, material choices, and competitive positioning in the growing electric crossover segment.
This Equinox EV underbody analysis isn’t just about what’s visible—it’s about the deliberate engineering decisions that lie beneath. Engineers, EV enthusiasts, and OEM stakeholders alike will find insight here, especially as design efficiency and crashworthiness evolve for mass-market EVs.
Built on BEV3, but Diverging in Execution
Though it shares GM’s BEV3 platform—also used by the Honda Prologue—the Equinox EV exhibits meaningful structural differences. One of the most striking is the cradle design. The Equinox uses a clamshell stamping configuration that is relatively linear, efficient for material use, and includes weld piercings and reinforcement layering to control crush dynamics.
While the Honda Prologue opts for a different cradle weldment strategy, the Equinox’s design emphasizes tailored crash response and cost efficiency. A key example is GM’s choice to stop one particular cradle stamping short and weld on a separate section. This indicates either the use of higher-grade steel or an intent to meet specific crush or deflection targets—an unusual but deliberate trade-off.
Front-End Structure and SORB Considerations
Up front, the Equinox EV features a stamped steel impact structure with mandrel-bent lower reinforcements and crush cans integrated into the cradle. Unlike some earlier Bolt EVs that included a triple crush can array for SORB performance, the Equinox uses a splayed engine bay rail approach.
That splaying—combined with features like scalloped weld flanges, pedestrian protection speakers, and a gently flaring cross-car member—points to a body structure designed with multiple regulatory and dynamic load scenarios in mind. The front rail grows in section as it moves outward and interfaces directly with the cradle.
Of particular note is the use of scalloped panels and castellation for drainage, weld access, and weight savings. These lean design elements echo what Munro saw in Alpha-platform Camaros and Cadillacs—small, efficient stampings that contribute to a rigid yet light structure.
Smart Use of Materials: Steel, Aluminum, and Polymer
The Equinox EV mixes material types to meet cost, NVH, and strength requirements. Its front drive module (EDM) mounts show an intelligent blend—polymer bushings in the front, cast aluminum mounts in the rear. This asymmetry likely improves NVH isolation during specific motor movements without sacrificing durability.
Similarly, the lower ball joint uses aluminum—an unusual choice for a cost-sensitive crossover. Whether for crash scripting or shape-driven packaging constraints, it’s another example of GM prioritizing performance even at the component level.
Shielding strategies also reflect production realities. Instead of localizing abrasion shielding with tape, the Equinox’s cooling lines are fully sleeved in nylon—a choice likely driven by supplier convenience and assembly consistency.
Battery Pack Integration and Protection Strategy
The battery pack—estimated at 85 kWh—is composed of multiple stampings welded and sealed together, rather than a single monolithic tray. This modular approach allows family part sharing across Ultium-platform vehicles and reduces tooling costs.
Where some OEMs go heavy on shielding, GM takes a different path. The high-voltage connectors are relatively exposed near the front of the pack. Though it’s assumed all OEMs validate these areas for debris and water intrusion, the visible vulnerability of these connectors is worth noting—especially for those with off-road or harsh-weather use cases.
From a structure standpoint, the cradle mates almost directly with the battery pack, sharing bolting and double shear plate points to maximize rigidity. The battery housing’s inner hat sections and nesting zones appear engineered for modularity and forward compatibility with other vehicle designs.
Rear Suspension: Multi-Link, Hydroformed, and Thoughtful
The Equinox EV uses a traditional five-link rear suspension setup—somewhat premium for this segment. Most of the links are tall stamped steel hat sections, while the camber link is a forged piece. This combination yields strength where needed and keeps cost manageable elsewhere.
More intriguing is the hydroformed rear rail structure. While Honda’s Prologue uses clamshell stampings for similar architecture, GM’s hydroforming allows for smooth diameter transitions and strategic flattening—ideal for packaging constraints near isolator mounts.
Hydroforming also facilitates double-shear mounting plates and precise load path management, especially where the rear crossmember connects to the bulkhead and transitions into the rear rail. This area is crucial for crash performance and suspension geometry retention.
Design Efficiency and Lean Manufacturing
Throughout the underbody, GM’s use of smaller, segmented stampings—sometimes sealed, sometimes scalloped—is a masterclass in lean manufacturing. Like past GM platforms (Alpha, Lambda), the Equinox prioritizes panel nesting, minimized flange overlap, and lightweight reinforcement.
These decisions reduce blank size, simplify tooling, and enable multi-vehicle platform strategies. They also enable weight reductions without relying heavily on expensive materials like aluminum or carbon fiber.
The MacPherson strut in front and multi-link rear show that GM is willing to mix tried-and-true architectures with modern packaging. Efficient routing of brake lines, use of isolated cradles, and smart shielding all contribute to a vehicle that balances cost, safety, and ride quality.
Synthesis: Competitive and Strategic Engineering
From a teardown perspective, the Equinox EV underbody is not revolutionary—but it is smart. Every weld joint, scallop, or crush can reveals a trade-off evaluated by GM’s engineering and cost teams. Whether it’s opting for hydroforming over clamshells, integrating lighter polymers for NVH, or nesting panels for scalable stamping—this is thoughtful engineering aimed at mass-market EV dominance.
For automotive engineers and teardown analysts, the Equinox EV is a valuable benchmark in modern EV design. Its divergence from the Honda Prologue—despite shared architecture—speaks volumes about brand identity, cost targets, and manufacturing partnerships.
Equinox EV Underbody Analysis Takeaways
- Unique cradle design separates the Equinox from its BEV3 sibling, the Honda Prologue.
- Scalloped weld flanges and segmented stampings reduce weight and support lean design.
- Polymer-aluminum EDM mount pairing suggests targeted NVH management.
- Hydroformed rear rails provide packaging flexibility and crashworthiness.
- Five-link rear suspension offers handling performance in a price-sensitive EV.
Team Up With Munro!
Curious how this compares to other Ultium-based vehicles? Watch our full Equinox EV underbody review on Munro Live—and check out Munro & Associates for expert teardown insights across the EV landscape.