Dürr is all set to supply highly automated final assembly technology for Volvo Cars’ first-ever all-electric vehicle plant in Košice, Slovakia, as the automaker prepares to begin production at the new facility in 2027.

 

The project will bring together Dürr’s international engineering teams to deliver an integrated final assembly solution covering conveyor, filling and testing technologies. The aim is to help Volvo Cars produce electric vehicles with greater efficiency, precision and reliability.

 

The Košice plant is designed to produce up to 250,000 vehicles a year. It is part of Volvo Cars’ strategy to expand its global manufacturing footprint as the company works toward a fully electric vehicle lineup.

 

Dürr will provide turnkey planning and implementation across several final assembly processes, reducing the need for coordination between separate technology suppliers. Its NEXT.assembly concept combines consulting with modular conveyor, assembly, filling and testing technologies into a single integrated solution.

 

Volvo Cars will use Dürr filling technology that has already been deployed at several of its plants, including the automaker’s facility in Torslanda, Sweden.

 

The Košice systems are being designed with future requirements in mind. They will be capable of handling new low-conductivity coolants and next-generation air-conditioning refrigerants expected to be required under future European legislation.

 

Dürr will also supply its vehicle geometry and headlight alignment technology for end-of-line inspection at Košice.

 

“Volvo Cars has exceptionally high standards when it comes to measurement accuracy. We are very familiar with these standards, as Dürr equips all Volvo sites worldwide with vehicle geometry and headlight alignment technology,” says Jörg Neumann, Director of End of Line (EOL) Product Line at Dürr in Germany.

 

The plant will use Dürr’s x-wheel system to measure and adjust chassis geometry with high precision. Its x-3Dsurface non-contact sensor enables area-based measurements across different tire and body shapes.

 

The system will also determine the driving axis used to set headlamp alignment. As increasingly sophisticated headlamp designs incorporate more LEDs and a wider range of functions, accurate light measurement is becoming more critical.

 

Dürr’s x-light system addresses those requirements with camera-based technology that checks the low beam, high beam and fog lamp, then enables semi-automatic adjustment in line with ECE and SAE standards.

 

At the heart of the final assembly operation will be a complete Dürr conveyor system connecting the plant’s individual production stages.

 

More than 3 kilometres of conveyor technology will move vehicle bodies and doors through final assembly, using electric monorail systems, skillet platforms and modular chain conveyors.

 

The system is built around robust, low-maintenance components designed to deliver high availability while keeping operating costs under control. Dürr says the result will be a stable, synchronized material flow across the final assembly process.

 

“Our fully automated final assembly system represents a significant advancement in automotive manufacturing, combining precision engineering with cutting-edge automation to deliver exceptional quality and efficiency,” says Andreas Hohmann, CEO at Dürr Italy and Vice President of NEXT.assembly.

 

With production scheduled to begin in 2027, the Košice project marks another step in the rapid shift toward dedicated electric-vehicle manufacturing—and positions automation and integrated production technology at the centre of Volvo Cars’ new European operation.