How the Volkswagen ID. Buzz Nails Efficient Underbody Packaging

When it comes to electric vehicle (EV) design, underbody packaging is where functionality meets engineering artistry. The Volkswagen ID. Buzz—a retro-inspired, forward-thinking EV van—demonstrates how a large vehicle can excel in cost-effective, space-conscious engineering. In this teardown analysis, the Munro team walks us through the underbody architecture of the 2025 VW ID. Buzz, offering key insights for automotive engineers, EV enthusiasts, and cost-focused manufacturers.

Cost-Efficient Design Decisions Up Front

At first glance, the front fascia of the ID. Buzz stands out for its minimalist yet effective design. A two-tone paint finish gives it a nostalgic flair. But such aesthetics aren’t just about style. In fact, they involve deliberate manufacturing costs. Masking and painting are expensive processes, and Volkswagen’s decision to streamline this through molded black plastic inserts and simple layering reveals a judicious approach.

In the lower fascia, the expanded polypropylene (EPP) foam is left exposed. This is unconventional. Many OEMs hide such components for aesthetic reasons. But VW’s decision here is purely functional. Given the low visibility of the part, concealing it offers no real customer-facing value, making the exposed configuration an intelligent cost-saving move.

Moreover, there’s no active grille shutter system — a common inclusion in modern EVs for aero performance and EPA credits. Instead, the cooling module remains visible, protected only by a modest injection-molded screen. VW’s approach here again shows how they prioritize practical engineering over costly extras.

Modular Architecture and Material Choices

Removing the front aero shields reveals a steel-intensive structure, starting with the crash stanchions and cradles. The ID. Buzz uses a mostly steel front cradle with large, efficient weldments. This choice reflects a cost-focused strategy — avoiding expensive aluminum parts while retaining structural integrity.

The front suspension features a MacPherson strut setup, complete with a single-ply stamped steel control arm — an uncommon sight on large EVs. This choice allows VW to nest tooling, reducing manufacturing complexity and cost. The cast knuckle includes an integrated crash feature, further streamlining the structure.

VW’s strategic use of injection-molded plastic is also noteworthy. A structural plastic bridge supports high-voltage air conditioning components and spans the cradle. It’s a clever lightweighting solution that integrates multiple components into a single carrier, saving both space and weight.

Rear-Wheel Drive Adaptability

The reviewed ID. Buzz variant is rear-wheel drive, though VW does offer an all-wheel drive version. The RWD configuration provides additional packaging challenges, as there’s no front drive unit. This leads to interesting thermal management routing and underbody line placement.

Coolant lines piggyback on a rear cradle, connected with a network of hoses, check valves, and pumps. While functional, our team at Munro suggests that a blow-molded or injection-molded manifold could reduce weight and complexity — especially if volumes justify retooling. The current setup, while serviceable, is likely a compromise driven by timing and production scale.

Battery Integration and Structural Synergy

The battery pack uses a tightly integrated cooling plate and protective shield, likely shared with the ID.4 platform. Fasteners every 300mm secure the battery shield to cross-car structures, including seat risers and B-pillars. This strategy allows the battery to play a load-bearing role in crash protection and body rigidity.

Teardrop-shaped swaged holes function similarly to NACA ducts, reducing wind noise and aiding thermal management. This level of integration, where aerodynamics, cooling, and structure interact, underscores the sophistication behind seemingly simple panels.

Rear Drive Unit and Compact Suspension

Moving rearward, the ID. Buzz reveals a cleverly packaged rear-drive module. The trailing arm suspension and offset gearbox sit incredibly close to structural and NVH components, maximizing cabin space while maintaining dynamic performance.

The packaging here is among the tightest Munro engineers have seen, with trailing arms, sway bars, and high-voltage lines all sharing millimeters of tolerance. A unique welded end rod for the sway bar is especially novel — efficiently capturing lateral movement within a compact bushing.

Volkswagen’s use of steel over aluminum is consistent, though where aluminum is used — such as large integrated components — it offers substantial value. The sway bar bushings may be overmolded or swaged steel collars, ensuring durability despite their compact design.

Rear Impact Strategy and Axle Details

At the vehicle’s rear, stamped steel bumpers and injection-molded absorbers create a lightweight but effective crash zone. However, the tight confines leave little room for extended energy absorption, meaning that moderate impacts may still reach the liftgate or structural frame.

The presence of a rear drum brake with an integrated motor-gear unit (MGU) for the electronic park brake is a fascinating decision. While drums are largely phased out, their lower cost and proven functionality may be re-entering EV design. Our engineers note that as industry capacity for legacy components dries up, returning to older tech can be paradoxically costlier — unless you’re already set up for it.

NVH and Corrosion Prevention

Throughout the underbody, PET-based NVH mats and wax sealants appear in key areas. VW uses limited, targeted sealing — employing wet joints and waxed seams to prevent corrosion without overengineering. This selective strategy mirrors approaches seen in other German OEMs like BMW and Mercedes-Benz.

One surprising element is the deliberate exclusion of paint on some structural steel components, resulting in surface rust even on early-stage vehicles. We attribute this to cost savings — painting might add over $2.50 per axle — and the parts’ thickness ensures long service life regardless.

Lessons for EV Engineers and Manufacturers

The Volkswagen ID. Buzz underbody teardown offers several key takeaways:

1. Efficient packaging is critical in large EVs, especially vans. Every inch matters, and VW shows how to prioritize space without sacrificing strength or function.

2. Material pragmatism rules. VW’s preference for steel and structural plastics, alongside selective aluminum use, demonstrates cost awareness without performance compromise.

3. Component reuse and modular thinking across platforms (like MEB vs. MQB) help amortize engineering costs and support scalable manufacturing.

4. Serviceability trade-offs exist. While some areas could be simplified with molded manifolds or reduced line complexity, these decisions often depend on take rate and production timing.

5. Old tech can make a comeback, like drum brakes, if they meet packaging and cost constraints.

Final Thoughts: The Buzz Behind the ID. Buzz

Volkswagen’s ID. Buzz is more than a nostalgic nod to its iconic microbus. It’s a masterclass in modern electric vehicle design; where every structural bracket, stamped panel, and molded plastic piece serves a functional, cost-driven purpose. This is lean engineering at its best: no fluff, just smart, scalable design.

For engineers and investors watching the EV market, the ID. Buzz provides a compelling case study in how underbody design can shape performance, assembly efficiency, and long-term sustainability.

Want more deep-dive EV insights?

If you’re curious about the evolving landscape of EV architecture, keep watching Munro Live for what’s coming next from the MEB platform. And keep and eye on Munro & Associates for more teardown breakdowns, cost analyses, and expert reviews you won’t find anywhere else.