agent Entrepreneur logo
MenuMENU
SearchSEARCH

EV Startups Adopt New Approach to Manufacturing

EV companies, Arrival and Fisker, embark on paths designed to circumvent production challenges experienced by Tesla.

by Ronnie Wendt
August 19, 2021
EV Startups Adopt New Approach to Manufacturing

Arrival has decided to build electric van and bus "microfactories" to produce its vehicles.

Credit:

Arrival

3 min to read


Electric car and van startups seek to avoid Tesla’s manufacturing troubles by taking very different approaches to mass production.

During 2017 and 2018, Tesla struggled to ramp up volume production for its Model 3 sedan. The automaker contended with automation troubles, battery issues and other bottlenecks, and even had to construct a new line in a tent outside its facility to meet production targets. The issues nearly broke the company.

Ad Loading...

New entrants in the EV game have found better ways to deal with these challenges.

Some companies found investors willing to fork over billions to fund production. Rivian, for instance, raised about $10.5 billion from Amazon, Ford Motor Co. and others to ramp up production of electric vans, pickups and SUVs.

Startups lacking investor support identified other inexpensive paths to mass production.

Usually, automakers spend over $2 billion to build a factory big enough to manufacture 240,000 vehicles or more annually. EV startup, Arrival, has decided to build electric van and bus “micro-factories” instead. These small plants cost $50 million and do not use expensive equipment. Arrival makes its vans out of lightweight colored plastic composite, eliminating the need for paint shops.

Arrival raised around $660 million in a public offering in March. The company used the funds to build two U.S. plants, one in North Carolina devoted to building vans for the United Parcel Service and another in South Carolina producing buses. The company also plans to build a factory in Spain. Arrival’s first micro-factory in Bicester, England, acts as a blueprint for the other plants.

Ad Loading...

The lack of a paint shop is just one way Arrival keeps production costs down. Its engineers also build molds for plastic body panels. These molds cost thousands of dollars versus millions for traditional metal dies. Engineers have also designed custom molding machines.

The company needs around 70 robots per micro-factory. Arrival purchases commonly used, generic robots from auto industry suppliers like Kuka and Italy’s Comau, which is owned by automaker Stellantis, to do the work.

Arrival’s micro-factory will have one adhesive station and the autonomous wheeled robots will carry a chassis back and forth throughout the assembly process.

The smaller manufacturing facilities can produce 10,000 vans annually per plant rather than 100,000. Each micro-factory will create around 250 jobs.

Electric vehicle maker Canoo has adopted a similar strategy. The company plans to build a mega micro-factory that serves as a hub for smaller future factories.

Ad Loading...

Electric Last Mile Solutions will launch a small electric van production facility later this year. The company plans to reassemble pre-finished vehicles made in China at a former GM plant in Mishawaka, Indiana, adding new seatbelts and other safety features to meet U.S. regulations. Over time, the company will incorporate more American parts into the vehicles.

Other startups plan to outsource manufacturing to trim production costs. Contract manufacturing deals reduce upfront costs with partnering companies later taking a cut of revenue and potential profits.

REE Automotive Holding entered agreements with American Axle and Mitsubishi Motors to build its electric platforms for delivery vehicles and people movers at scale. While REE and Fisker have teamed up with Magna International to build EVs. Fisker also has a similar agreement with Foxconn Technology.

 

Originally posted on Auto Dealer Today

More Sales

Nissan SUV in a tunnel
Salesby Lauren LawrenceMay 29, 2026

Nissan Reports Significant Sales Growth

Following the release of Nissan’s 2025 fiscal year report, the automaker announced that its retail-first approach has led to a significant jump in dealer sales.

Read More →
Orange BMW with windshield wipers sticking up.
Salesby Hannah MitchellMay 18, 2026

Inventory of New Units Stable

Auto brands spent April clearing out most of their 2025 supply with incentives while holding firm on 2026 prices, striking a balance to meet demand and protect their bottom lines.

Read More →
two men in suits shaking hands
Salesby Peter ChafetzMay 1, 2026

The Hidden Edge

Reflections from the 2026 Agent Summit: gratitude, gut decisions, and the power of the first contact

Read More →
Ad Loading...
Photo of white 2026 Ford Bronco on a sandy beach
Salesby Hannah MitchellApril 10, 2026

March New-Vehicle Sales Don’t Reflect War

Cox Automotive data shows Americans doubled down on big-is-better despite price increases. Slightly higher incentives helped fuel the demand.

Read More →
car with hood open, an arm holding a wrench, The most loyal generation text, Agent Entrepreneur logo
Salesby Lauren LawrenceApril 9, 2026

Service Drives Gen Z Loyalty

The dealership profit center plays an important role in customer retention, and generation Z customers are showing the highest loyalty rates, based on recent CDK Global data.

Read More →
chart showing the quarterly electric vehicle market share from 2020-2025
Salesby Lauren LawrenceMarch 27, 2026

EV Sales Slide While Hybrids Climb

California, as usual, led the country in EV registrations in the fourth quarter, but the U.S. as a whole saw a 43% year-over-year volume decrease.

Read More →
Ad Loading...
car in the background with two people exchanging a set of keys and one person holding a clipboard with paperwork that says "Contract". Text says Buyout Beats Leasing. Agent Entrepreneur logo in top right corner.
Salesby Lauren LawrenceMarch 26, 2026

Lease Buyouts Deemed Favorable

Better financing conditions and the potential to save money on monthly payments could drive more consumers to buy out their vehicle leases instead of opting for a new lease payment.

Read More →
Graphic showing used-vehicle days to turn rate
Industryby StaffMarch 10, 2026

Black Book: Weekly Market Update

Both vehicle values and conversion rates sped up last week as two segments outperformed in the pre-spring burst of buying.

Read More →
Salesby Lauren LawrenceMarch 4, 2026

Used-Vehicle Program Aims to Draw More Buyers

GM says more than 750 dealers across the U.S. are enrolled in CarBravo and that in January CarBravo dealers sold over two times the certified volume of Chevrolet, Buick and GMC dealers using traditional CPO.

Read More →
Ad Loading...
SalesFebruary 25, 2026

Creating Agency Loyalty

There are tried and true ways to instill it while also protecting your agency from competitors and other roadblocks.

Read More →