Skip to content 
As electric vehicle design matures, automakers continue pushing the boundaries of modularity, material optimization, and aesthetic integration. Nowhere is this more apparent than in the Hyundai IONIQ 9 — the latest three-row entry from Hyundai’s growing EV lineup. In this teardown and hoist review, Munro & Associates examines the vehicle’s structural makeup, thermal strategies, suspension layout, and packaging choices. The Hyundai IONIQ 9 teardown reveals a compelling balance between platform commonality and bold styling decisions, aligning with Hyundai’s lean design philosophy.
Modular Styling Meets Platform Uniformity
At first glance, the IONIQ 9’s visual identity stands apart — with stainless-look threshold moldings, gloss black trim bands, and contrasting body colors. But beneath the surface, Hyundai cleverly reuses key elements from its existing E-GMP platform. Body-colored panels are accentuated by black accents in a deliberate rhythm, often masking structural elements like aluminum extrusions beneath aesthetic tapes or stickers. This attention to styling is not purely cosmetic — it reflects a calculated effort to deliver a premium look while maximizing existing component use.
Interestingly, Munro’s teardown reveals that Hyundai applies die-cut black stickers to conceal visible portions of the aluminum battery housing. While this may seem like a minor decision, it signals Hyundai’s nuanced understanding of consumer perception. Where raw aluminum might suggest sportiness on a suspension control arm, it can be visually distracting under the vehicle’s flanks. In the IONIQ 9, appearance management complements cost-effective structural reuse.
Battery Integration and Thermal Strategy
Underneath, the battery pack is integrated directly into the chassis, both bolted and sealed in place. Engineers noted a polypropylene glass-filled thermoplastic sheet covering sections of the battery’s underbody — a likely cost and weight optimization. This material balances thermal insulation, impact resistance, and manufacturability while serving as a visual cover.
Additionally, Hyundai uses thermal tape and cladding around battery extrusions, offering both protection and temperature management. From a lean manufacturing perspective, this kind of lightweight shielding — combined with strategic airflow paths — allows Hyundai to simplify its cooling systems while maintaining thermal safety margins.
Cooling lines run rearward along the battery’s length, terminating at the rear HVAC module. These lines, along with brake line junctions, are strategically routed within structural troughs to protect them from debris and ensure modular assembly. The integration of a THX valve and three-way interface mimics multi-manifold setups found in more complex systems like Tesla’s octovalve — but remains simplified in its bracket-based mounting.
NVH Countermeasures and Rear Drive Module
At the rear, the IONIQ 9 sports a compact drive module paired with a visible inverter and gearset. Noise, vibration, and harshness (NVH) management is a clear priority. Engineers identified die-cut acoustic pads made of EPDM and closed-cell foam placed strategically around the inverter and gearbox. This insulation likely mitigates electrical whine and gear chatter, particularly during low-speed operation or regenerative braking events.
Hyundai appears to rely on gear profile design and targeted insulation rather than expensive gearing changes. As the rear unit is not the primary drive source, some gear cost optimizations may be offset with external NVH treatments. This balanced approach keeps costs low while maintaining acceptable noise levels — a consistent Hyundai strategy.
Suspension Strategy: Balancing Cost and Capability
Suspension design in the IONIQ 9 continues Hyundai’s trend of mixing material technologies for optimized value. At the rear, multi-link control arms vary between aluminum and steel, depending on trim level and market. The aluminum knuckles offer reduced unsprung weight, improving ride comfort and handling response, while stamped or folded steel arms reduce cost without sacrificing geometry precision.
Front suspension layouts on this platform often adopt McPherson struts — a proven formula for cost-effective control and simplified assembly. While the teardown didn’t focus explicitly on the front, consistency across Hyundai’s E-GMP vehicles suggests a similar arrangement here.
These modular suspension strategies allow Hyundai to toggle between premium and base trims with minimal engineering changes — a core tenant of lean manufacturing. This adaptability also supports global scalability, making the IONIQ 9 viable across different regulations and customer preferences.
Platform Reuse with Creative Top-Hat Variations
Despite the unique styling, the IONIQ 9 retains a familiar E-GMP architecture underneath. From the front load rails and cradle structure to the rocker panels and C-pillar geometry, the modular underbody remains largely untouched. What changes dramatically is the “top hat” — everything visible from the side glass up.
Hyundai leverages this upper-body modularity to differentiate products like the IONIQ 5, IONIQ 6, and now IONIQ 9. The teardown confirms that these top hats are designed to interface cleanly with the shared platform — including mounting points, crush can locations, and shock towers. This approach maximizes tooling ROI and allows for dramatic styling changes without requiring full vehicle revalidation.
Designers can explore bolder rear treatments, tailgate angles, and greenhouse profiles, knowing the underlying crash structure and drivetrain mounting points remain consistent. As a result, Hyundai can deploy new models quickly and with reduced engineering overhead.
Lean Design Observations
Several design details in the teardown highlight Hyundai’s lean engineering ethos:
-
Aluminum concealment with stickers: Aesthetic masking that doesn’t interfere with structure or cooling.
-
Glass-filled polypropylene shielding: Cost-effective protection with integrated thermal resistance.
-
Die-cut acoustic foams: Cheap, easy-to-apply NVH solutions placed only where needed.
-
Common bracketry and fastener strategies: Simplifies service, assembly, and supplier logistics.
-
Modular control arm layouts: Support trim-based cost scaling and localized supply chain optimization.
Each of these elements reflects a manufacturer focused not just on part cost, but on lifecycle cost, tooling versatility, and end-user perception.
Final Thoughts: Hyundai’s Quiet Engineering Advantage
The Hyundai IONIQ 9 isn’t trying to shock the world with one revolutionary component. Instead, it builds on years of EV experience — refining, reusing, and repackaging core technologies in a modular, scalable way. From an engineering perspective, this approach enables Hyundai to stay nimble, cost-competitive, and stylish across multiple global markets.
For automotive engineers, the key takeaway is Hyundai’s balance between aggressive styling and conservative structural reuse. For EV investors and enthusiasts, it’s further proof that the E-GMP platform has legs — capable of scaling up to larger SUVs while retaining manufacturing efficiency. And for the teardown community, the IONIQ 9 confirms that thoughtful details — like acoustic treatment and composite shields — still matter when chasing margin and quality perception.
Discover More Expert Teardowns and Insights
Subscribe to Munro Live or explore the world of Munro & Associates for expert insights and in-depth analysis. Dive into detailed lean design breakdowns and gain hands-on access to the future of automotive innovation. Whether you’re an engineer or an enthusiast, there’s always more to discover behind the scenes of next-gen mobility.