There’s a fight for control going on inside the cockpits of many modern cars. Enable all the active safety systems in a Tesla, and it’ll do most of the steering for you. But if it makes an errant turn or meanders a little too far this way or that in the lane (and trust me, it will), you’re left wrestling the wheel out of Autopilot’s virtual hands.
Assistance systems from other manufacturers do better at ceding control whenever you feel like taking over, but BMW is about to take that to a new level with the first car built on its upcoming Neue Klasse platform. It includes an advanced driver assist system that the company says is a proper symbiosis, where the car’s sensors and systems don’t fight with or yell at you but instead work with you to make driving safer and less stressful.
I sampled this suite in a prototype of BMW’s iX3, the first electric SUV on the Neue Klasse platform, designed from the ground up to offer more range, better handling, and way more smarts. BMW is promising 400 miles of range from a new battery architecture that can charge at up to 400 kW. That means adding something like 200 miles of range in 10 minutes, but there’s a lot more to it than that.
At the core of the iX3’s safety system is a computing platform that BMW calls a “superbrain.” That’s an evocative term for a Qualcomm Snapdragon Ride chip, but it does offer far more power than anything the company has put on the road before. That’s paired with a more advanced sensor suite, with better cameras and higher-fidelity radar sensors, all combined to give a better view of the world around.
One of those key sensors is the driver monitoring suite, which can detect where you’re looking and whether you’re paying attention while behind the wheel. Plenty of cars offer some degree of monitoring like this, usually nagging you with beeping and blinking unpleasantries when your eyes linger on a roadside distraction for too long. The iX3 goes beyond that by using eye-tracking technology to not just complain, but actually improve your experience.
If you’re driving down the highway and BMW’s highway assistant is active, it’ll steer itself and even change lanes. In some current BMWs, you can just look in the mirror to initiate a lane change. The iX3 takes that a step further by proactively putting on the turn signal for you should you take the wheel and change lanes yourself.
Yes, finally, a BMW designed to tackle the most common preconception about BMW drivers: they never signal before changing lanes.
Try to change lanes manually without checking the blind spot, the lane-keep assistance system will resist the change and try to keep you where you are. But, if you’ve looked first, the car won’t resist your control at all, as you’ve proved to it that you’re doing your part.
The car will detect your attention in other ways, too. I had a chance to drive next to a dummy pedestrian standing partially in my lane. Without any input from me, the car came smoothly to a stop. But, when I tried again, steering slightly to the left and showing that I was paying attention, the car allowed me to move out of the lane without resistance.
I also got a chance to sample the other brain inside the new iX3, which the company has unfortunately labeled “Heart of Joy.” This in-house developed processor aggregates all the traction, stability, and electric motor management functions that are typically handled by a dozen different processors sourced from a dozen different suppliers and scattered throughout the car.
Unifying all that has some significant implications. The car can more quickly and seamlessly manage power to the dual motors that give it 400 horsepower and all-wheel drive, so when I was sliding the camouflaged prototype around a wet test track, it felt like the stability and traction control systems were working to help me, rather than just trying desperately to slow me down.
But when it was time to pause the action, something almost magical happened. On a test track, I was told to close my eyes and let the iX3 bring itself to a stop. That process of deceleration was so smooth that I genuinely couldn’t tell when the wheels had stopped rolling. The new systems controlling those electric motors allow more precise application of the regenerative braking function. That not only means smoother one-pedal driving, but the kind of perfectly controlled stop that’ll keep your passengers from getting jostled at every red light.
Ultra-smooth stopping is a small thing, but it really does increase the comfort of driving around in the iX3. By the end of the day, I was blown away by everything BMW’s new EV brings to the table. And that’s on top of the big, dashboard-spanning Panoramic Vision display, which runs from one pillar to another to provide a customizable and interactive information display.
The big question, though, is whether any of this will be enough to convince the largely EV-skeptical luxury car buyers out there that all this is good enough to finally make the switch away from internal combustion. The company’s gas-powered X3 is consistently one of its top sellers, and while that isn’t going away, BMW clearly has high hopes that the iX3 will bring that kind of sales success to its battery-powered efforts.
But it’s just the first of multiple models planned on this Neue Klasse platform, all with the same combination of tech and finesse. If they’re successful, maybe the world can finally put that BMW blinker stigma to bed for good.
]]>Alright, we get it. Y’all are excited about Slate. We thought the little Slate Truck was cool, but based on the number of clicks and comments on our Slate Auto articles so far, you’d like to know more. Many of you wrote in with questions and more than a few people raised some doubts.
So, we wanted to address as many of those as we could. Here’s your one-stop shop for Slate answers based on your questions — plus a few of our own.
The Slate is clearly a vehicle built for everyday utility, and while it’ll make for a handy machine for hauling a lot of things, big towing and heavy cargo were clearly not a top priority. Here are the key specs, compared against the four-wheel drive hybrid Ford Maverick with the 2.5-liter engine and a Ford F-150 4×2 with a 2.7-liter EcoBoost V6.
Slate Truck | Ford Maverick | Ford F-150 | |
Horsepower (hp) | 201 | 191 | 325 |
Curb weight (lbs) | 3,602 | 3,674 | 4,171 |
Max payload (lbs) | 1,433 | 1,500 | 1,775 |
Max towing (lbs) | 1,000 | 2,000 | 8,400 |
Bed length (ft) | 5 | 4.5 | 5.5, 6.5, or 8 |
Bed width (max / min, in) | 50 / 54.9 | 42.6 / 53.3 | 50.6 / 66.9 |
Seats | 2 | 5 | 5 |
It’s worth noting that these Ford numbers vary widely based on configuration. For example, you can get a “4K Tow Package” on the Maverick that boosts towing to 4,000 lbs, and the F-150 has hundreds of variations depending on need. Max towing on an F-150 is 13,500 lbs. The numbers above represent the figures quoted by Ford for a base, option-free vehicle.
And one final note: towing substantially reduces the efficiency of the tow vehicle, due to the weight of the trailer and its additional aerodynamic drag. For an electric vehicle like the Slate, that will surely result in reduced range, perhaps by as much as half depending on the trailer.
Slate has confirmed manufacturing will take place in a former catalog printing facility in Warsaw, Indiana, which closed in 2023. Slate hopes to renovate the facility and eventually employ 2,000 workers, with an annual production volume of 150,000 vehicles. And the company is seeking tax abatements on the factory site from the county government to begin construction. Full details on that here.
That domestic production should mean that vehicles produced by Slate are eligible for the full $7,500 federal rebate — if the credit still exists late next year when the Truck enters production.
No, the Slate Truck does not have built-in cellular connectivity. LTE is an increasingly common feature in new cars, enabling auto manufacturers to do all sorts of stuff, including good things like software updates and some perhaps not so good things like selling your driving data.
For the former, o-the-air updates will still be possible via the Slate smartphone app. Updates will be downloaded to the phone and then pushed to the Slate Truck via USB cable. As for the latter, that leads us to our next question.
Not your driving data, no, but you can upload data about the health of your vehicle. Jeff Jablansky, Slate Auto’s head of public relations and communications, gave us this example:
“A ‘check engine’ light comes on: if the driver has their phone plugged in and has opted in to data movement, the company will send a notification to the Slate app so they can be aware of potential service needs.”
Jablansky confirmed that no data will be sold to third parties.
One of the joys of owning a modern EV is easy preconditioning. Regardless of where your car is parked, you can get the interior warmed up or cooled down from just a few taps on your smartphone, all without having to worry about filling your garage with carbon monoxide.
Can you do that in the Slate Truck? Maybe. The lack of cellular connection means you won’t be able to wirelessly connect to your Truck from anywhere, but Jablansky didn’t rule it out entirely, saying, “This is something we are working on through the app.”
Ready to download some STL/3MF files today and start designing your ultimate cupholder? Us, too, but we’ll need to be patient for a little bit. “The Maker community is incredibly important to Slate, and we are on track toward delivering on this commitment closer to launch,” Jablansky says.
So stay tuned on that front. Jablansky says this will also include details on third-party accessory providers and licensing.
The DIN slot, also known as the ISO 7736 or Deutsches Institut für Normung 75490 slot, has long been the standard for in-dash audio. Why, then, are there no DIN slots on the Slate Truck? Slate says it was to offer greater flexibility. “We wanted to allow the customer to pick and choose their accessories without forcing combinations of options together in packages. This comes to life in our audio strategy to allow customers to choose to install anything from a Bluetooth speaker to a full audio system,” Jablansky says.
So the bad news is if you want to use a standard DIN receiver, then you’ll need to DIY an enclosure for it. The good news is if you just want to mount a Bluetooth sound bar, then you won’t have to worry about filling any gaping rectangular holes in the dashboard.
No. “Consistent with our broader approach, we focused our engineering to make a Slate a great truck to drive,” Jablansky says.
Keep those hands on the wheel, folks.
Cost and simplicity, it turns out. Jablansky says that “a two-door form factor meant less material, less complexity, lower cost.” He adds that the lockable frunk means there’s sedan-like secure storage for your stuff, with the added benefit of a big bed out back. And, of course, you can add on the SUV kit if you need more seating or more covered storage.
Per Jablansky, special tools are not expected to be required.
It’s a dynamic world and dynamic industry out there right now, but Slate isn’t backing down. “We are committed to our expected price point of $20,000 after federal incentives,” Jablansky says, which implies an MSRP of roughly $27,500. “If incentives go away, Slate will remain well-positioned in the U.S. with a strong proposition of value, safety, and customization.”
Will those attributes be enough to woo people away from a Ford Maverick, which starts at just over $28,000? We’ll have to wait and see.
Jablansky says that Slate is also committed to US manufacturing, which should fend off most of the tariff fears, and that the company is still on track to start manufacturing in 2026.
]]>Back in March, we brought you an exclusive look into how Chevrolet’s engineers tuned and tweaked, sculpted and simulated to turn the eighth-generation Corvette into a 233-mph missile, the 1,064-horsepower ZR1. But while I’m a racing simulator fan through and through, there’s nothing like driving a real car on a real track, and this past week it was time to do exactly that.
That track, the Circuit of the Americas (COTA) in Austin, Texas, is as real as it gets. Host of the Formula One United States Grand Prix since 2012, it’s three and a half miles of sinuous asphalt with enough turns to see just how well those engineers sorted the car’s handling, plus a long back straight just perfect for letting that big motor really sing.
COTA is also the perfect place to test out the ZR1’s downforce, something that wasn’t so much of a factor leading up to the car’s record-breaking 233-mph run. More downforce means more grip, which is always nice, but it usually comes with the penalty of aerodynamic drag.
That’s one reason why there’s actually two different ZR1s. First is the base model, with just the (relatively) petite spoiler on the back of the trunk lid. Then there’s what Chevy calls the ZTK trim with the Carbon Fiber Aero Package. This includes the massive rear wing you see here, plus numerous other aerodynamic bits and pieces. In exchange for a lower top speed (you’ll need the base car if you want to go 233 mph) you get a whopping 1,200 pounds of downforce.
To balance out the wing, an effective scoop up front replaces the frunk found in lesser models of the Corvette. On the ZR1, air is ducted upward through the hood and over the windshield. This helps keep the nose stuck at speed, which in turn helped me accelerate quickly.
Before I really got on the power, I took just a single familiarization lap of the track in a ZTK-equipped ZR1. That was enough to warm up the tires and myself before I really got into it. On the next lap, I hit 175 mph on COTA’s back straight, then pulled more than 1.5 Gs of deceleration when I hit the brakes.
Those are world-class performance figures. Braking that hard feels like someone’s turned the world upside down — or at least spun it 90 degrees.
The forces while cornering are nearly as violent. The seemingly endless sequence of right-hand corners toward the end of a lap really test your fitness in the ZR1. Pulling over 1.3 G in the corners means your neck is going to get a real workout.
By the way, these are all numbers that I verified using the in-car Performance Data Recorder, which not only captures a high-definition view forward of your on-track antics but overlays numerous points of telemetric data and also embeds all that data for later analysis, just like the pros.
The numbers on that telemetry and the feelings I got inside the car confirm that this is a level of performance unlike any Corvette before. Despite that, it’s still very much a Corvette in that all its performance is approachable. It only took one lap to get comfortable diving into the corners, routinely pushing past the tires’ limits and quickly recovering to make the next turn without too much drama.
The advanced traction, stability, and ABS systems on the ZR1 are a big part of that. Far from the fun-killing electronic aids we’re used to on the track, these systems worked to make me faster, really only letting themselves be known by the occasional blinking light on the dashboard. Even with the aids on, I could still kick the tail out when coming out of the slower turns before launching down the subsequent straights.
There is one big disappointment in the new ZR1, though: It ships first as a 2025 model, which means it comes with Corvette’s old interior, including the unfortunate row of buttons that awkwardly bisects the cabin. 2026 Corvettes feature a thoroughly revised and improved layout, including a new triple-screen layout.
The ZR1 will get that new interior, but not until the 2026 cars appear later this year. So, if you have the $174,995 to get yourself into a ZR1, I’d suggest waiting until the second model year, hard as that may be.
]]>In The Andromeda Strain, Michael Crichton wrote about killer alien space crystals that are (spoiler alert) ultimately stymied by Earth’s breadth of pH values. In reality, crystals grown in space could be key to a new generation of cancer-fighting treatments that save lives, not threaten them.
Colorado-based startup Sierra Space is nearly ready to launch its reusable space plane, Dream Chaser. It’s set to carry into orbit a 3-D printed module designed by engineers at pharma giant Merck. If the test goes well, and if Dream Chaser’s gentle reentry process keeps that sensitive cargo safe, this could be the start of something big — despite those crystals being microscopic.
Space crystals sound like something an astrology guru would hang over their bed to help them sleep, but there’s real science here. According to the ISS National Lab, crystals grown in space are simply better: “Scientists hypothesize that these observed benefits result from a slower, more uniform movement of molecules into a crystalline lattice in microgravity.”
Research into monoclonal antibodies points towards crystallization as being key for developing more stable, subcutaneous delivery mechanisms. Theoretically, expensive chemotherapy sessions could be replaced by injections that a patient could self-administer at home.
It’s the stuff of science fiction — and in the case of The Andromeda Strain, it literally is — but the truth is actually closer to Back to the Future. Space crystal research actually began in the early ’80s, first on one-off rocket flights and eventually on the Space Shuttle.
Space crystal research actually began in the early ’80s
There was much hope (and hype) about the tech back then, but it was ultimately stymied by two things. The first is cost. The Space Shuttle orbiter was to be America’s low-cost orbital research transporter, but that never panned out. NASA’s own per-mission costs pegged each flight at somewhere around $1.5 billion. That’s simply far too expensive, even in the pharma industry, where reporting quarterly profits often requires seven or more digits.
The rise of SpaceX and its competitors has brought those costs down substantially, lowering the cost of getting cargo into space to a relatively paltry $2,000 per kg. But that still leaves the other problem: shock.
If you’re going all the way to orbit just to grow some ultrafine structures, you don’t want to rattle them to pieces on the way back down.
“It’s about a 20 mph car crash equivalent into the ground,” Dr. Tom Marshburn said of the experience of landing in a capsule like Dragon. He would know. Marshburn is chief astronaut at Sierra and the company’s VP of human factors engineering, but before that he was a NASA astronaut. He’s flown on the Shuttle, Soyuz, and Dragon.
Sierra and its reusable Dream Chaser aircraft stand poised to fix both problems, cost and shock, in one fell swoop.
Those of us of a certain age will likely feel a sort of irrational affinity for Dream Chaser at first glance. Its black and white color scheme and simple, lifting body design give strong Space Shuttle orbiter vibes, but this is no retro design intended to earn throwback cred. Dream Chaser has some major advantages over Shuttle.
For one thing, it’s much smaller, about one-quarter the length. It fits neatly inside a payload compartment of a ULA (United Launch Alliance) Vulcan rocket, not requiring the messy combination of tanks, liquid and solid fuel boosters, and endless specialized hardware that stymied any hope the Space Shuttle had in being profitable.
It also doesn’t require a three-mile-long runway like the Shuttle. “It can do a precision landing anywhere a 737 can land,” Dr. Marshburn said.
“It can do a precision landing anywhere a 737 can land.”
The biggest change, though, is that it won’t fly with crew onboard. For now, at least. Dream Chaser was born out of the Commercial Crew Transportation Capabilities (CCtCap) contract, a competition that also included SpaceX’s Dragon capsule and Boeing’s Starliner capsule. NASA selected two winners, and Sierra Space was unlucky to place third.
However, seeing the potential, NASA offered enough orbital cargo contracts to make a Dream Chaser reboot worthwhile. A subtly redesigned space plane will launch and land as planned, just minus the people.
Why did NASA want to keep Sierra Space in the loop? Dream Chaser’s design offers some real benefits, particularly as we potentially enter an age of space manufacturing. “A capsule like a Dragon, by the nature of the physics, of the shape of it, can bring down only half of what it takes up,” said Meagan Crawford, founder and managing partner at SpaceFund, an early-stage venture capital investment fund with a focus on commercial space. “The space plane has the opposite physics, it can bring down twice as much as it takes up.”
An ideal orbital transport and manufacturing network, then, has a combination of the two.
That’s the potential. For now, the project with Merck is something of a proof of concept, a 3D-printed module containing a series of tubes, plungers, and capsules. Once it gets to the ISS, a willing astronaut will turn some valves in sequence, then the resulting concoction will be shuttled back to Earth for someone at Merck to examine.
And they’ll be able to do so quickly. Dr. Marshburn said that traditional reentry capsules like Dragon or Soyuz often spend days bouncing on boats or trucks before their cargo can be retrieved. Dream Chaser was designed for cargo to be offloaded within an hour after its wheels stop rolling.
The Merck module will test that quick retrieval, plus the soft landing, ensuring the potential for this sort of crystalline growth in space. And, though the ISS is itself set to be decommissioned by the end of the decade, Sierra Space is positioning its own inflatable orbital modules as a commercial alternative, free of the politics and oversight of the ISS.
Space Fund’s Crawford said that the economics are sound, and the proof is in the number of players trying to capitalize on the space plane market. Startups like Venus Aerospace, Radian Aerospace, Dawn Aerospace, and Virgin Galactic each have their own aircraft in development, with goals ranging from cargo to space tourism.
Space drug development has the potential to be hugely promising, but Sierra has a few other arrows in its quiver. It’s partnering with Honda to get a next-gen fuel cell into space, and those of you craving smaller and better processors could be in luck too. A startup called Space Forge plans to grow processor substrates in orbit, another area where gentle touchdowns are key. In shattering today’s mission cost barriers, Sierra Space might just blow through the semiconductor nanometer barrier, too.
There’s hope for one more type of cargo to come out of these missions. For now, Dream Chaser is relegated to transport only cargo, but the stumbles of the Starliner program could reopen the door to hauling humans.
“You see a winged body and of course, astronauts, especially test pilots, we want to be in that,” Dr. Marshburn said. “At any point, we’d be able to leverage the work that’s already been done to get that ready.”
If that does come to pass, it’ll take some time. Tenacity, the first Dream Chaser, is going through final checks at NASA, waiting for its chance to head to the ISS sometime later this year. The second, Reverence, is currently under production.
In other words: Watch this space.
]]>Since Slate Auto came out of stealth mode last week, the internet has been abuzz with speculation about the finer details of the ultra-barebones electric Truck, which is set to cost just $20,000 when it enters production next year — assuming our federal EV incentives are still in place by then.
One of those questions was where Slate will build the thing, with a TechCrunch report suggesting a factory in Indiana. Today we can officially confirm the details. Slate Auto will retrofit an existing 1.4 million square foot factory in Warsaw, Indiana, where the company plans to eventually produce 150,000 Trucks annually.
If you missed all the excitement last week, Slate’s Truck is a radically simplified EV with 150 miles of range, a barebones machine that could be considered a minimum viable car. It has no touchscreen, no radio, no power windows, and no paint.
Slate Auto will retrofit an existing 1.4 million square foot factory in Warsaw, Indiana.
Those were some of the concessions required to make an EV that inexpensively in the United States, but some of those seeming compromises enable a uniquely streamlined production workflow.
Because the Truck doesn’t have paint, Slate Auto’s factory doesn’t need an expensive paint shop. (Mercedes-Benz recently spent a reported $1 billion building a new one.) And, because the body panels are made of a form of plastic, that factory can skip the massive presses typically used to stamp metal body panels into shape.
Slate will build out their production hub at the former R.R. Donnelly facility in Warsaw, Indiana, a printing press that was once responsible for stuffing your mailbox with catalog pulp from retailers. It shuttered in September of 2023, putting over 500 people out of work.
When it reopens next year, Jeff Jablansky, Slate Auto’s head of public relations and communications, says the plan is to employ 2,000 people at the facility. Slate wouldn’t confirm the total investment the facility’s retrofit will require, or the terms of Slate’s use of the property, only that renovations will cost in the hundreds of millions of dollars.
All that will need to be completed before the Truck can begin production, which is currently scheduled for Q4 of 2026.
At 1.4 million square feet, Slate’s facility is roughly one-quarter the size of Tesla’s Fremont Factory, which currently produces approximately 650,000 vehicles per year. Again, Slate hopes to produce upwards of 150,000 Trucks annually at this facility, an annual production rate that took Tesla more than five years to achieve in Fremont. Given its simplified manufacturing process, Slate will surely be hoping to move more quickly.
Slate is committed to not only manufacturing the Truck in the U.S. but to using domestic suppliers as well. “The vehicle is designed, engineered, and manufactured in the U.S., with the majority of our supply chain based in the U.S.” Jeremy Snyder, Slate’s Chief Commercial Officer, told us ahead of the Truck’s debut. As global trade wars only escalate, that’s looking like a sound move.
]]>Ask just about anybody, and they’ll tell you that new cars are too expensive. In the wake of tariffs shaking the auto industry and with the Trump administration pledging to kill the federal EV incentive, that situation isn’t looking to get better soon, especially for anyone wanting something battery-powered. Changing that overly spendy status quo is going to take something radical, and it’s hard to get more radical than what Slate Auto has planned.
Meet the Slate Truck, a sub-$20,000 (after federal incentives) electric vehicle that enters production next year. It only seats two yet has a bed big enough to hold a sheet of plywood. It only does 150 miles on a charge, only comes in gray, and the only way to listen to music while driving is if you bring along your phone and a Bluetooth speaker. It is the bare minimum of what a modern car can be, and yet it’s taken three years of development to get to this point.
But this is more than bargain-basement motoring. Slate is presenting its truck as minimalist design with DIY purpose, an attempt to not just go cheap but to create a new category of vehicle with a huge focus on personalization. That design also enables a low-cost approach to manufacturing that has caught the eye of major investors, reportedly including Jeff Bezos. It’s been engineered and will be manufactured in America, but is this extreme simplification too much for American consumers?
If you haven’t seen the leaks and the reports of weirdly wrapped trucks hiding in plain sight, the Slate Truck is the first product from Michigan-based Slate Auto. Think “American kei truck” and you’re not far off. It’s a machine designed to be extremely basic, extremely customizable, and extremely affordable. Those are not your typical design goals, but then the Slate Truck isn’t the fruit of your typical design process.
Wander through any automotive design studio anywhere in the world and you’ll inevitably come across a mood board or two, sweeping collages of striking photos meant to align the creative flows of passers-by. They’re a tool for helping a disparate design team to create a cohesive product, but where many such mood boards feature glamour shots of exotic roads and beautiful people, front and center in the Slate’s mood board was something different: a big, gray shark, covered in scrapes and scars.
“It looks like a shark that has definitely been in more than one brawl and clearly has come out ahead because it’s still swimming,” says Tisha Johnson, head of design at Slate and who formerly spent a decade at Volvo. That aesthetic, of highlighting rather than hiding battle scars, is key to the Slate ethos.
Instead of steel or aluminum, the Slate Truck’s body panels are molded of plastic. Or, as Slate calls them, “injection molded polypropylene composite material.” The theory is that this makes them more durable and scratch-resistant, if only because the lack of paint means they’re one color all the way through. Auto enthusiasts of a certain age will remember the same approach used by the now-defunct Saturn Corporation, a manufacturing technique that never caught on across the industry.
Slate continues the theme through to the upholstery, too, a heathered textile that was designed to get better looking as it wears. The idea is to lean into the aged aesthetic.
But not everybody will dig the shark theme, and so the Slate Truck is designed to be customizable to a degree never seen before on a production vehicle. Johnson says this is in contrast to the overly curated experience offered by many brands.
She says over-curation by automotive designers results in situations like premium, luxury cars that are only available in a palette of disappointingly bland colors: “There’s usually only a fraction that you actually want, and those are always more expensive,” she says.
Disparaging other brands for offering limited color choices might seem disingenuous coming from the designer of a vehicle available in a single shade. The Slate Truck, though, was designed to take advantage of the current trend of vinyl-wrapping cars. Its simple shape and minimal trim pieces mean that even amateurs can do the job. Slate will offer DIY kits that newbies can slap on in an afternoon and replace just as quickly based on mood.
However, the biggest benefit of this monochromatic thinking might come in production.
It’s probably no surprise to you that building cars is expensive. Elon Musk loves to bemoan just how complicated the process can be whenever Tesla is late shipping its next new model, but he’s far from alone in that assessment.
What is a little less commonly known is just how expensive it is to paint those cars. Creating a facility that can reliably, quickly, and cleanly lay down a quality coat of color on automotive body parts is a complicated task.
That task has only gotten more complicated (and thus expensive) in recent years, with greater environmental regulations and consumer expectations forcing manufacturers to find ways to offer more vibrant hues with less ecological impact. Mercedes-Benz just announced it’s building a “Next Generation Paintshop” at its Sindelfingen plant in Germany, and estimates place the thing’s cost at nearly $1 billion.
By eliminating paint, and thus eliminating the paint shop, Slate’s manufacturing process is massively simplified. So, too, the lack of metal body parts. “We have no paint shop, we have no stamping,” says Jeremy Snyder, Slate’s chief commercial officer who formerly led Tesla’s global business efforts.
Vehicle factories tend to have high ceilings to make room for the multiple-story stamping machines that form metal body parts. Injection molding of plastic is far easier and cheaper to do in limited spaces — spaces like the factory that Slate has purchased for its manufacturing, reportedly near Indiana. “The vehicle is designed, engineered, and manufactured in the US, with the majority of our supply chain based in the US,” Snyder says.
The simplification goes simpler still. Slate will make just one vehicle, in just one trim, in just one color, with everything from bigger battery packs to SUV upgrade kits added on later.
“Because we only produce one vehicle in the factory with zero options, we’ve moved all of the complexity out of the factory,” Snyder says.
While most buyers will rightly fixate on the cost of the truck, the bigger story here might just be this radically simplified approach to manufacturing. “From the very beginning, our business model has been such that we reach cash flow positivity very shortly after start of production. And so from an investment standpoint, we are far less cash-reliant than any other EV startup that has ever existed, as far as I know,” Snyder says.
As Slate tries to dash to production without tripping over the headstones of failed EV startups that litter the countryside, that leanness is key. It’s helped them attract some major investors. “The greatest industry magnates to invest in our company,” Snyder says. He declined to name names, but according to a TechCrunch report, one of those magnates is Jeff Bezos.
“We don’t have a direct connection to Amazon,” Snyder clarified, but he didn’t rule out some corporate cooperation. “Who knows? Who knows if you’ll be able to purchase on Amazon? I don’t know.”
Those vinyl wraps are literally just the first layer of what Slate’s designers are positioning as a, well, blank slate. They want owners to personalize every aspect of the vehicle, including its silhouette.
Need room for more than two passengers? Slate has an SUV upgrade kit that will bolt onto the back of the truck, adding extra rollover crash protection and rear seats with seat belts to match, all in a package that’s easy to install at home.
No, this isn’t a Subaru Brat redux. The seats will be forward-facing, and the whole setup is supposed to be strong enough to meet crash test regulations. In fact, Slate’s head of engineering, Eric Keipper, says they’re targeting a 5-Star Safety Rating from the federal government’s New Car Assessment Program. Slate is also aiming for a Top Safety Pick from the Insurance Institute for Highway Safety.
This will be, in large part, thanks to a comprehensive active safety system that includes everything from automatic emergency braking with pedestrian detection to automatic high beams.
A mandatory part of today’s safety features is a digital rear-view camera. Typically, this view pops up on a modern car’s central infotainment screen, but the Slate doesn’t have one of those. It makes do with just a small display behind the steering wheel as a gauge cluster, which is where that rearview camera will feed. You’ll have physical knobs for controlling the in-cabin temperature controls plus the typical turn stalk and other switchgear, but that’s about it.
The truck not only lacks a touchscreen for infotainment duties, it lacks any form of entertainment at all beyond whatever fun you can get from the 201-horsepower, rear-drive configuration. There’s no radio, no Bluetooth, and no speakers of any kind beyond for those required to play basic warning chimes.
Many will consider this a cost-cutting step too far, but the interior was designed for ease of upgrading, with easy mounting space for anything from a simple soundbar to a full sound system.
There’s an integrated phone mount right on the dashboard, but there’s nothing stopping you from bringing something even larger. I expect the low-cost Android tablet and 3D-printing communities to have a field day coming up with in-car media streaming solutions.
The rather extreme omission of any kind of media system in the car is jarring, but it, too, has secondary benefits.
“Seventy percent of repeat warranty claims are based on infotainment currently because there’s so much tech in the car that it’s created a very unstable environment in the vehicle,” Snyder says.
Eliminating infotainment, the theory goes, necessarily boosts reliability. And reliability will be key because Slate is taking DIY to new extremes on the maintenance front, too.
The right to repair your devices is a massively important topic for everyone from smartphone users to smart tractor operators. Traditionally, auto manufacturers haven’t exactly gone out of their way to make DIY maintenance easy, partly because their dealers make so much money hawking cabin air filters and unnecessary coolant flushes.
As an EV, the maintenance schedule for Slate Truck should be minimal (most EVs don’t need much more than an annual tire rotation), but for any warranty concerns, the company will encourage users to do the fixes themselves. At least when it’s safe to do so.
“If you’re not going to break the vehicle and you’re not going to injure yourself, meaning high voltage, you can do service and warranty service on your vehicle yourself and have the videos and the helpline to support you to do that work,” Snyder says.
That support network will be called Slate University and it’ll teach you everything you need to know. Don’t fancy yourself a shade tree mechanic? Or maybe you don’t have a tree to park under in the first place? Slate has a partnership with already-established nationwide service centers, where owners can take their trucks for any needed fixes. Upgrades can be performed here as well, including installing an extended-range battery that will bring the truck’s maximum range up to 240 miles.
“At start of production, we will have coverage across the country for servicing your vehicle,” Snyder says. Snyder declined to say who will provide the service, but it seems reasonable to expect something along the lines of a Midas, Monro, Meineke, or perhaps some other nationwide service chain that begins with the letter M.
And finally, how can you buy one? It should come as no surprise that Slate will follow Tesla’s footsteps by offering direct sales. No nationwide network of dealerships is planned. Instead, a limited set of pickup centers will pop up as needed based on preorder data. Or, if you don’t mind paying a little more, home delivery will be available.
Preorders cost just $50 on Slate’s site, and deliveries are expected to start in late 2026. Slate hasn’t said exactly how much the truck will cost, only that it’ll be less than $20,000 after federal incentives — assuming those incentives are still in place in 18 months’ time.
The bigger question, though, is whether consumers will actually be into such a simplified vision of what a car can be. The Slate Truck is a rolling rejection of the current, bloated state of American motoring, but it’s consumer demand that’s driven the market down this dark alley. Are those consumers ready for a rolling digital detox?
]]>If there’s one thing the auto industry hates, it’s uncertainty. When it takes upward of five or six years to bring a new car model to market, a certain administration throwing caution and global goodwill to the wind with a raft of unpredictable tariffs is decidedly bad news.
Right now, the US tariff situation is constantly shifting, with limited exceptions being granted for certain manufacturers whose leaders are willing to bend the knee. While there is talk of some potential relief, global auto manufacturers have yet to be given a reprieve from a 25 percent tariff on vehicles assembled outside of the United States.
This is an unprecedented situation, both in terms of the severity of the action and the swiftness with which it was enacted. It’s already had immediate impacts, like Audi holding foreign-made vehicles at port, and Jaguar Land Rover suspending all shipments to the US.
It remains to be seen which manufacturers will be most affected, but one thing is clear: car shoppers who’d been sitting on the fence about a new purchase are now rushing to their local dealers.
People like Andrew Neuberger, an Atlanta-area resident who works in the automotive software space, had a first-generation BMW X2 M35i that he was reasonably happy with. “I wasn’t planning on getting rid of the car for at least another year or two,” he said. “But as soon as I heard about the tariff situation, I started to consider accelerating things just due to the uncertainty of it.”
“I wasn’t planning on getting rid of the car for at least another year or two.”
Neuberger had hoped to wait for one of BMW’s next-generation EVs built on the upcoming Neue Klasse platform, which is not due to hit the market until late 2025 or early 2026. Instead, he went for the SQ6 E-tron from Audi. He said he was able to negotiate a reasonable lease price on the performance SUV and locked it in as early as he could.
According to data from Cox Automotive, which provides regular analysis of the global auto scene, new vehicle sales “surged” in March, “driven by strong seasonal trends and the urgency created by the import tariff announcement.”
The rate of new vehicle sales in March was up 17.2 percent over that in late February, with the average inventory of new cars dropping from 91 days’ worth at the beginning of March to 70 days by the end of it. In other words: dealer lots are starting to get picked clean.
EV sales were up 11.4 percent in the first quarter of 2025 year over year over the first quarter of 2024, and that’s despite Tesla sales bucking the trend and dropping 13 percent. Used car sales are booming, too, up 12.2 percent over the same period last year.
One of those purchases was made by John Osborn, who’s been looking for his unicorn: a Jeep Grand Cherokee Trailhawk. “I wanted a V8 in a non-grayscale color, which is a rare combination,” he said. He’d planned on waiting until the summer to find one. “Tariffs made it look like prices were going to go up, so I decided to move quickly and bought a car with my second choice color rather than wait indefinitely for the perfect spec to show up.” He took home a 2021 model last weekend.
In California, Steve Martegani had been thinking about adding a Mazda MX-5 Miata to his personal fleet but wasn’t looking to pull the trigger until the end of the year. That changed when he started reading about the tariffs. He was advised to move quickly by his Mazda dealer in Elk Grove. “That weekend, they had a significant increase in appointments and were expecting a big sales weekend,” he said. He put down a deposit on a car sitting at port instead of ordering one from Japan.
“Tariffs made it look like prices were going to go up, so I decided to move quickly.”
Martegani’s dealer was not the only one seeing the rush. Alan Valenti, general manager at Valenti Auto Group in Connecticut, which sells a spate of European brands including Audi, Jaguar, Porsche, and Volkswagen, said his sales teams are seeing an uptick in buyer interest and motivation.
“Lately, especially after COVID, when there’s uncertainty in the market, people think there might be a decrease in supply. They tend to maybe want to act sooner rather than later,” he said.
This is even hitting more niche brands. Valenti said his group’s Jaguar dealer had good inventory, but it’s “starting to get picked off.”
This is an evolving situation, but what was until recently a buyer’s market is rapidly shifting into the dealer’s court, according to Tom McParland, owner and operator at Automatch Consulting, which helps people find and negotiate car purchases.
McParland said he’s seen a significant increase in demand, starting days after the initial announcement of tariff action. “That weekend we had a huge scramble of folks wanting to get ahead of stuff and get deals closed,” he said.
He said that some dealers are doing the right thing and simply moving inventory quickly at fair prices, but others are taking more aggressive action, raising prices even on cars that were imported well before the tariff was announced.
Ford and Stellantis are bucking the trend by offering employee pricing to all. But where there were discounts to be had on many models not long ago, things are different today, according to McParland. “Deals are expiring rapidly,” he said.
“Deals are expiring rapidly.”
He also fears that other incentives, like cash-back offers or special financing rates, may go away even for American-made cars as manufacturers try to keep things balanced and offset the increased cost of other models — a concern we’ve also heard from other experts.
It’s not a great situation if you’re in the market, but McParland does have a few tips. First, if you find an acceptable deal, pull the trigger. “Don’t step over a fair deal waiting for a better one,” he said.
And second, follow Osborn’s lead on his Jeep purchase, and don’t hold the line waiting for your perfect specification. “The more flexible you are, the better your chances,” he said. “The pickier you are, you’re probably going to pay more.”
And what about the unlucky souls who placed an overseas order for their perfectly configured dream car, which hasn’t been fulfilled yet? You’d better call your dealer if you haven’t already and make sure that the price you negotiated is locked in, because you might be in for a surprise.
]]>Marques McCammon has a lot to prove. He’s president of Karma Automotive, a position he began in 2023, taking the lead of a company that’s had a turbulent history, to say the least. He has an aspirational goal: to make Karma into America’s ultra-luxury vehicle manufacturer. “There is not an Aston, Ferrari, McLaren, or Lamborghini class of vehicle in the US,” he says.
This would be yet another reboot for a company born out of Henrik Fisker’s failure. No, not that failure, but the one that came before. The Fisker Karma launched in 2012 and was immediately heralded for being one of the best-looking and most-innovative grand touring cars on the planet.
Praise didn’t lead to success. The brand went bankrupt just a year later, its assets sold off and relaunched as Karma Automotive in 2016. Its primary product is still basically that same car, though it’s gone through a few name changes. What was originally the Karma became the Revero, then fell victim to an alphanumeric rebranding to GS-6 in 2021. Today, it’s just Revero again.
“There is not an Aston, Ferrari, McLaren, or Lamborghini class of vehicle in the US.”
It’s a turbulent history for a car with an interesting architecture, a series hybrid design that paired relatively small battery packs of various sizes smaller than 30kWh, depending on configuration, with a 1.5-liter, three-cylinder engine sourced from BMW.
That engine, though, didn’t turn the wheels. It only provided enough additional electricity to extend the Karma’s range out to 360 miles. A few other cars, like the Chevrolet Volt and BMW i3, experimented with this approach, but it never really caught on.
Today, the series hybrid is suddenly trendy, though now referred to as an extended range EV or EREV. Ram is positioning its Ramcharger, with an onboard 3.6-liter V6, as a solution for big towing range without a gigantic battery. Likewise, Scout Motors says its optional Harvester EREV is the solution for potential buyers suffering from premature range anxiety.
But Karma Automotive, née Fisker, was doing it before it was cool, and McCammon says the EREV’s time has finally come. He points to the Chinese market as proof. “BYD came in with EREV, their highest selling units were EREV vehicles, and they were eating market share away from all the BEV guys, Tesla in particular,” he says. (BYD sold 4.2 million vehicles globally in 2024, more than twice as many as Tesla.)
McCammon hopes to capitalize on that momentum, refocusing the company’s efforts around EREVs. Karma had previously announced the launch of a fully electric model called Kaveya, ditching the range extender for a bigger battery and 1,000 horsepower worth of electric motors. That car, now, isn’t coming until 2027.
McCammon says this isn’t a delay, but a response to market demand. Karma will bring out its full EV after other players in the premium luxury performance space bring theirs to the party. “We know that a certain company that likes the color red and prancing horses is coming out with an EV. So we’re going to move our EV sports coupe to be just behind them,” he says.
If you’re going to fast-follow, Ferrari’s a good one to shadow.
So it’s out with the Kaveya and in with the Amaris, which debuts today. It’s an EREV like the Revero but powered by a new engine. The three-cylinder, BMW-sourced unit is out, replaced by a four-cylinder that McCammon says offers more power and character.
“So you think of Shelby’s Cobra, the Viper, the side port of exhaust is kind of an American signature,” McCammon says. “So that’s something we’re going to bring back.”
In the past, the small-displacement engines in series hybrids would drone along at a set RPM — a speed chosen for efficiency, not for acoustics. The result is a grating sound that manufacturers traditionally try to hide, not highlight.
“We know that a certain company that likes the color red and prancing horses is coming out with an EV.”
That engine will charge batteries with a new chemistry optimized for frequent charging and discharging, and the car will offer full power until there’s less than five miles of range left in the battery pack. “If I can’t take it to the track and do a couple of laps around it and enjoy myself, then it’s kind of a waste,” McCammon says.
The sourcing of those batteries, though, could prove problematic. While Karma builds its own battery packs at its Moreno Valley, California, factory, it buys the individual cells from a supplier. McCammon says that Karma will stop sourcing cells from China by the end of the year, and while the new supplier is closer to home, it’s not domestic.
“I honestly did not anticipate wondering about tariffs within the Americas,” McCammon says, a common refrain right now across numerous industries. The current trade war of retaliatory tariffs with US neighbors to the north and south could complicate Karma’s plans.
That could result in higher prices, but the Amaris will be a substantially more expensive car regardless. Though its overall architecture and design are similar to the Revero, it’s set to be more premium across the board, including a body made of carbon fiber rather than aluminum, better materials on the interior, and a host of new tech.
There’s a showy new 4K display inside the cabin and a new system architecture for the drivetrain system relying on fewer, more powerful processors. McCammon says those chips would only come from a US source, but given his time at former Intel subsidiary Wind River, and given Karma’s prior agreements with the company, the Amaris having Intel inside seems like a safe bet.
The Amaris is set to go on sale late next year, when it will join another new model, the Gyesera, a long and low grand tourer that will replace the Revero. Gyesera was initially planned to be an EV, but it will instead stay the EREV course like its predecessor.
Gyesera goes into production sometime before the Amaris, meaning Karma is going to have to soldier on for the rest of 2025 with the Revero. This year marks its final run of 160 cars, 30 in a higher-end Invictus trim, with upgraded Ohlins suspension, bigger wheels, and enough other goodies to raise its price to $185,000.
That’s a significant bump over the base Revero’s price of $123,100 and a lot of cash for a car that’s basically 13 years old. But then you can spend as much on a new Tesla Model S, a machine that is likewise substantially the same as it was in 2012.
But it’s the Amaris that really marks the true way forward for the brand. Next year feels like a long way off, given how long the company has been promising new and exciting things. Skeptical? McCammon says he doesn’t blame you, but he’s here to change your mind.
“Normally, in the auto industry, we hold our plans really close to the vest, and we only let you see it right when we’re about to deliver. I’m choosing to put the vision out there, so everyone sees exactly where I’m going, and basically put my neck on the line,” he says. “Hold me accountable.”
]]>There’s an unbelievable amount of work going on right now to boost the performance of lithium-ion batteries. PhDs around the globe are, at this very moment, furrowing their respective brows, trying to eke out a few percentage points of extra energy density, shave a few minutes off of charging times, or add a few months to a given cell’s effective lifespan.
And then along comes a startup called Breathe Battery Technologies with an algorithm that promises to boost charging speeds by upward of 30 percent, all while preserving the lifespan of those cells. It’s part of a software package light enough to run on ancient embedded systems and small enough to be deployed via over-the-air updates. Best of all, it’s not theoretical: Volvo will feature this tech on the company’s upcoming ES90 sedan, and you can already find it on some smartphones.
Here’s how it works.
Before we delve into the details, let’s quickly run through exactly what’s happening inside a battery. The charge provided by a battery happens when ions flow from anode to cathode, then journey across the electrolyte while carrying electrons with them. When it’s time to recharge, the process is effectively reversed, shoving those ions back across the void as quickly as possible.
These processes generate heat, and while some heat is fine, too much can damage the battery. Overheat your cells? Best case, their lifespan is reduced. Worst case? Well, you’d better stand back.
Charging, and particularly fast charging, is a careful dance between wasting time by charging too slowly and damaging the battery by charging too quickly. In most EVs, that dance is choreographed by a lookup table.
Similar to the fuel injection tables of yore that dictate how much juice to squirt into the cylinder for each combustion cycle in an engine, battery tables say precisely how much current should be applied to a given cell at a given temperature and state of charge.
The problem is, those tables aren’t very good.
To use these tables, you must know the battery’s temperature and state of charge. Find those figures, and the table tells you how much current can be applied to recharge the battery. It literally defines the charge curve for the cell. These tables are developed by the companies that make the cells (like Samsung SDI or LG Energy Solution) and the companies that put them in their cars.
The problem is that these lookup tables can be vague, lacking specific values for every temperature and state of charge. A lack of data fidelity makes for imprecise results. It’s like trying to draw a beautiful, flowing curve, but you can only use a few straight lines.
The tables are also inflexible, covering a narrow range of temperatures. “If you start with a table, you are fundamentally locked into the dimensions of that table. You are really bottlenecking yourself from the very get-go,” Ian Campbell, the CEO of Breathe, said.
Battery tables say precisely how much current should be applied to a given cell at a given temperature and state of charge.
Additionally, cars often waste a lot of energy to keep the batteries in a very narrow temperature range just to optimize the use of the lookup table. “You need to heat up or cool down the battery in order to prepare for this fast charging, and that also consumes a lot of energy,” Björn Fridholm, technical specialist in battery management at Volvo, added.
That takes us back to Breathe and its special sauce. You’re still working with the same basic factors: voltage, temperature, and current. Here, though, a software package (called Breathe Charge) determines the ideal charging rate with much more precision across a wider performance envelope than could be reasonably contained within a table.
“So you end up with this incredible level of fidelity and adaptivity across all timescales,” Campbell said.
To resurrect the metaphor from above, instead of jagged lines, you can now draw flowing charging curves that more closely match the ideal performance of the individual battery cells.
By mirroring that curve, cars equipped with Breathe’s tech will charge faster without putting any additional stress on the battery cells. And by providing a wider range of data, cars can charge more quickly even when outside their ideal thermal windows.
How much more quickly? Breathe and Volvo say this tech delivers a 30 percent reduction in charge time when going from 10 to 80 percent on a high-speed charger. But Breathe’s algorithm also delivers even bigger improvements when operating outside of ideal conditions. At zero degrees Celsius, that charge time improvement was 48 percent.
Why isn’t everyone doing this? It comes down to two constraints, the first being a deep enough understanding of the behavior of the individual cells. To gather that data, Breathe has a pair of labs in London where it stress tests sample cells from manufacturers.
Breathe determines a given cell chemistry’s strengths and weaknesses, breaking those chemical attributes into computer data, which drives the company’s digital physics model.
That then takes us to the second constraint: system overhead. While manufacturers and chipmakers love to talk about cars becoming supercomputers on wheels, the reality is that most of today’s cars still rely on embedded systems, dated chips with limited memory, and specs closer to yesterday’s graphing calculators than today’s GPU-laden rigs.
“If you start with a table, you are fundamentally locked into the dimensions of that table. You are really bottlenecking yourself from the very get-go.”
Efficiency is key. Breathe’s algorithm requires minimal processor cycles and fewer than 10 kilobytes of memory. The lightweight nature means that Breathe’s tech can be run on all sorts of limited hardware, even deployed via over-the-air updates — assuming those integrated systems are smart enough to be reflashed remotely.
Getting that efficiency means reliance on industry simulation and physics modeling tools, primarily MATLAB and Simulink. However, Campbell said that Breathe (which currently numbers about 75 employees) is working on future versions for the faster automotive processors to come.
Many of these future automotive processing chips also deliver some aspect of onboard AI, but it isn’t on the roadmap for Breathe. Campbell said he’s “bullish” on machine learning tech in this application but that it isn’t quite ready yet.
But the biggest constraint is the battery cells themselves. The amount of current they can receive is dictated by their construction and chemistry. Breathe Charge doesn’t violate the laws of physics; it simply ensures that the car is always feeding the right amount of current at the right time.
Volvo’s electric ES90, with Breathe Charge onboard, is slated to hit the market later this year. Fridholm confirmed the software could theoretically run on Volvo’s other EVs, including those already on the market, but he made it clear that we shouldn’t expect charge-boosting over-the-air updates hitting models like the EX30 anytime soon. “For now, we’re launching it on the ES90,” he said, and left it at that.
But Breathe won’t stop there. On its Careers page, the company currently has openings for sales-related positions in Detroit, Michigan — American auto manufacturers are clearly a target.
Breathe’s tech can also be found on the Oppo 8, where it’s optimized to extend battery health. Campbell said the company is also working to line up “a couple of cool customers” on the consumer devices front. In other words, hopefully we’ll be able to sample some fast-charging software in something a bit more affordable than a new Volvo soon.
]]>Last October, the Chevrolet Corvette ZR1 set a top speed of 233 mph on consecutive runs around a closed track. That’s not the fastest street-legal production car in the world: the Bugatti Chiron Super Sport 300+ will, as the name implies, top 300 mph. What’s special about the ZR1, then? Its $174,995 starting price may sound expensive, but it’s a steal compared to the Bugatti, which costs somewhere north of $4 million. The ZR1 is officially the world’s fastest production car available for less than $1 million.
The ZR1 achieved that speed on a massive test track in Papenburg, Germany, a place where the banking is so steep that the drivers suffered through 1.7 vertical Gs on the turns. That’s just one number out of an endless series of figures that the team behind that record-setting run calculated well in advance, tapping into simulations usually reserved for more utilitarian jobs, like figuring out how steep a grade a Silverado can tow up before blowing a gasket.
Here, the only number that really mattered was top speed — a figure that, in simulation, differed from reality by less than half of one percent. This is how they did it.
The Corvette has always been a machine punching above its weight in the competitive ring of international performance cars. I don’t mean that literally, as it is often the heaviest option within sports car shootouts. But, when compared to competitors from Porsche, Ferrari, and Lamborghini, the Corvette is the perennial value option, an everyman American choice out there making the world’s best look a little bit silly.
The ZR1, though, elevates that formula to another level with more power and better handling. While the code “ZR1” first appeared as an engine upgrade on the third-generation Corvette in the early 1970s — a limited option hardly anyone picked — it wasn’t until the C4 of the ’90s that the ZR1 appeared as the top-shelf trim of the Corvette.
The Corvette is the perennial value option, an everyman American choice out there making the world’s best look a little bit silly.
The first ZR1 was a revelation, compared favorably to period icons like the Ferrari 348 despite costing half as much. The latest ZR1 looks set to continue that legacy while raising the performance bar to new heights. You already know the thing’s top speed, delivered by a whopping 1,064-horsepower, 5.5-liter twin-turbocharged V8. Everything else has been upgraded to match, including carbon ceramic brakes, wheels made of carbon fiber, and sticky Michelin Pilot Sport Cup 2 R tires.
It’s a machine built to satisfy anyone’s need for speed. While its starting price means it’s hardly a good fit for every budget, it’s still outperforming machines that cost much, much more.
The months of work leading up to the test run began with one simple question: where in the world can you safely test a car like this?
Engineers at General Motors knew early that the new ZR1 was going to be the company’s fastest production car ever. The first problem was finding a safe place to find out exactly how fast. While GM has plenty of facilities of its own, including a 4.5-mile circle track in Milford, Michigan, the team behind the record-breaking run knew they needed somewhere bigger.
The High-Speed Oval at ATP Automotive Testing in Papenburg is certainly big. The track is 7.6 miles in total length, each straight running 2.5 miles before the asphalt turns back on itself. At 233 mph, those straights fly by in less than 30 seconds.
It’s the perfect playground for this sort of testing, but since it isn’t a GM-owned facility, the team wouldn’t have infinite time — just three hours spread over Friday and Saturday mornings.
The idea was to optimize everything in advance and calculate every detail from car alignment to tire pressure, leaving nothing to chance on the day of. “Go do this, and we’ll break some records,” Jason Kolk, simulation integration lead at GM, told me.
With the location selected, the simulations could properly begin. They started with a virtual model of every element of the car, which the team called a “virtual vehicle” — a digital twin to simulate aerodynamics and engine output as accurately as possible. “We even have a virtual ECU and controllers,” said Ping Hwang, GM’s performance systems integration engineer.
In a regular production car, these digital twins are primarily used to track changes during development and test reliability and efficiency. “The same physics model can be applied to towing, to range, to different temperatures,” said Wesley Haney, senior calibration engineer at GM.
It isn’t a single simulation that handles all this, but rather a suite, including off-the-shelf solutions like CarSim mixed with custom options written in C, Python, and even Fortran, a programming language that dates back to the 1950s and will surely outlive us all.
Despite the digital horsepower provided by GM’s high-performance computing centers in Michigan, it’s safe to say this application pushed all those tools to the limits. “We didn’t actually have a tire model that was run at that speed. Like, how much is the tire going to expand that speed?” Kolk said.
Fuel consumption can also be simulated, and there was a novel factor at play here: thrust. Running full-throttle at redline, the ZR1 generates 37 pounds of force from the engine exhaust alone. While that’s nothing compared to a SpaceX engine, every little bit helps when you’re trying to break records.
Beyond horsepower and thrust, aerodynamic drag is a huge factor. But Corvette engineers had already designed a low-drag aerodynamic package ideal for this application, ditching the ZR1’s big wing in exchange for speed. So, no tweaks were needed there.
The team first applied the simulations to runs on GM’s own circle track at Milford, where the car was soon lapping for real at 225 mph, already 13 mph faster than the official top speed of the ZR1’s previous generation.
Believe it or not, that was unwelcome news. According to the simulations, the car should have run faster.
Jake Hedrick, virtual propulsion engineer at GM, started poring over the data. After further investigation, he determined it wasn’t the simulation that was off, but the car itself. “What we were seeing is that, analytically, we were about 80 horsepower down,” Hedrick said. “That was due to multiple factors, but mainly driven by the spark calibration.”
“Spark” here refers to ignition timing, when the engine controller in the car tells the spark plugs to fire. If it’s too early, the explosive force of combustion fights the rotation of the engine. If it’s too late, you don’t get complete combustion of the fuel before the exhaust valve opens and the next cycle begins.
“We even have a virtual ECU and controllers.”
With this real-world data, the team optimized the engine mapping, unlocking the missing power the simulation said should have been there.
They also analyzed things like ride height and alignment, too. “We found if we lowered the car just a hair, we could get a tenth of a mile per hour,” Kolk said. But the team decided to leave that on the table due to time constraints.
That just left the question of weather, the one factor that the team couldn’t control. They could, though, look at historic trends. The team analyzed years of historic conditions to find the ideal time for their run: cool temperatures and low wind.
Wind is bad because, to set the record, the car’s speed is averaged over two runs in opposite directions. Any help you get from a tailwind will be more than negated when headed in the opposite direction.
“But our wind on Saturday was almost nonexistent. It was really ideal conditions,” Kolk said, setting the stage for speed.
The simulations had factored in everything possible and predicted everything they couldn’t calculate. The team even determined the optimal place on the track where the driver should open the throttle wide for the run, or “go to WOT” as the team put it.
But there was still the human variable. None of the simulations told the team just how stable or unstable the car would feel when going around the 50-degree banked turns at over 200 mph. The driver would need to put their foot to the floor well before they got to the straightaway.
“Would the driver feel a sense of like, ‘I can’t go to the pedal yet?'” Kolk said. “Or, if they went WOT too early, would that add a lot of heat to the system?”
Chris Barber, lead development engineer on the Corvette ZR1 and one of the drivers at the track, said that everything felt right from the beginning. “When we did our first actual 200-mph-plus test, all the drivers were so confident that we just went for it,” he said.
“It was amazing to just go to wide open throttle well over 200 miles an hour,” Barber said, describing what it was like to go screaming through the turn at three times the average highway speed limit and then putting his right foot to the floor. “You’re almost looking sideways at the sky… then once you get onto the straightaway, it just whizzes by so fast.”
“It was amazing to just go to wide open throttle well over 200 miles an hour.”
But there was a last-minute issue. During Friday’s test runs, the car was losing speed, coming up short of projections. The ZR1’s V8 engine is designed to run at 8,000 RPM. In the perfect world of the simulation, that’s fast enough to hit the maximum velocity of the Corvette. However, reality isn’t so smooth. With the tires skipping over bumps, the revs would spike, causing the car to hit the rev limiter. “Once you touch that limit, it wants to shut the party down, and it effectively ends the run,” Haney said.
To fix this, the team raised the rev limit by 100 rpm only in sixth gear, giving just enough headroom for the engine to bring the car to its top speed without stumbling. That raised redline, plus the revised engine timing, will all be part of the production ZR1, which will include a driving mode aptly called Top Speed.
With that, everything was set. But instead of relying on a test driver to make that final run, GM president Mark Reuss got the nod. The team wanted to show that it didn’t take a professional race car driver to extract this kind of performance from the machine. The final result, with Reuss at the wheel, was an average of 233.29 mph.
How does that figure compare to the simulation? When the team took the exact weather conditions and plugged them into the sim, the number was 232.2, just 1.09 mph off. The team thinks the difference comes down to the tire diameter increasing at speed, something the simulation can’t handle — not yet, at least.
Kolk said that result was proof that the simulations are absolutely on the money, which will help engineers optimize more pedestrian products to solve equally challenging problems. Aerodynamic and thermal performance are obviously key when you’re trying to top 230 mph on the track, but it’s even more important in some of the most complicated on-road challenges, like increasing the range of heavy-duty EVs when towing.
“We do all this work up front so we don’t have to worry about one system holding everything else back from achieving something really great,” Kolk said. Better simulations mean engineering teams can develop cheaper, lighter parts more quickly, iterating in the digital world rather than the physical.
So, while driving simulators are a good thing for gaming, they can certainly help you out in the real world, too. “That was by far my high score,” Barber said.
]]>