Volkswagen has developed an innovative underbody design for its purely electric ID.3. The large high-voltage battery is located beneath the passenger compartment and is protected from below by an aluminium sheet. The sheet represents the core of the completely encapsulated underbody. Its plastic covering not only protects against corrosion but also considerably improves aerodynamics beneath the vehicle, thereby also increasing its range.
If the ID.3 should sustain a side impact from another vehicle, the hybrid side members protect both the battery and the occupants. To reduce the weight, the side members are fitted with lightweight aluminium profiles on the inside and extremely lightweight yet ultra-high-strength steel is used. Even though the hybrid side members are dry areas, targeted corrosion protection measures are still applied here: the cathodic dip coating lines all cavities, while the inner sides of the sheet metal panels are additionally protected by wax flooding.
Volkswagen uses this range of tests and measures to secure the longevity of its models around the world – since no rust is not the norm.