Bonded aluminium monocoque

Unlike competitors built from conventional steel, LEVC products are built upon an anodised aluminium monocoque.

The aluminium components are glued together using an incredibly strong hot cure adhesive. The glue remains dormant until the entire structure is baked in an oven at 180°C for 20 minutes. Once cured, the adhesive becomes rock solid, turning the frame into a single, remarkably rigid structure.

This bonding process improves the vehicle’s strength, returning joints which are cohesive and well connected across the whole of the joint, rather than at single points.

Stronger, lighter, lasts longer

Weighing just 370 kg, the body structure effectively combines high torsional rigidity with lightweight construction.

Around 30% lighter than an equivalent steel structure, this delivers a crucial saving, especially in an electric vehicle, where most of the weight comes from the batteries. A conventional steel body and frame would add significantly more weight, decreasing performance and range.

The resulting bonds are more than twice as strong as traditional welding. This was tested on a 100mm aluminium strip, with the arrow representing the direction of the force applied. The upper welded joint failed at a load of 16kN. The bonded joint remains strong until around 34kN (3.4 tons) – under this force, the aluminium surface itself gives way.

Unlike steel, aluminium does not rust, and all 400+ aluminium components are anodised to further increase corrosion resistance.

The result is a van that stays productive for longer. In fact, VN5 can last twice as long as a conventional van – and its long life expectation will lead to excellent residual values.

The entire frame is made from recycled materials and is 100% recyclable – further boosting the green credentials of the product range.

Sheet Moulded Composite exterior

First-in-sector, the exterior body panels of LEVC products are made from a tough SMC material which is lighter, flexible and more resilient to light dents and knocks.

The high strength of the external structure gives it greater resistance to impacts which also means that damage to internal components is less likely in the event of an impact.

Quicker & easier to repair

Our vehicles are designed to resist damage, and be quick and easy repaired in order to minimise down time off the road.

Reference points are located in all of the key body structures. In the event of an impact we can use a portable measurement system to quickly verify whether damage is purely cosmetic and that the underlying structure has not been compromised.

The panel repair can then be confidently carried out by most body repair shops, without the vehicle being moved to a specialist bodyshop for appraisal.

If damage does occur, the most vulnerable panels such as the bumpers and rear quarter panels are attached by bolts, meaning they can be quickly and easily replaced – just like our previous models.

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