According to Mikael Fermér Volvo’s vehicle platform lead architect, the process will revolutionise the firm’s approach to construction. He noted that, at present, the fixed points and structures of a platform mean that it essentially has a shelf life once launched.

But because the megacast parts can be changed simply by adapting the moulds – which need maintenance every four months or so – it becomes much easier to make substantial changes to the structure, effectively giving a platform “an unlimited lifespan”. That could also lead to more rapid deployment of new vehicle types.

Volvo is aiming to increase the use of mega-casting in future years, with the ultimate goal of producing much of the platform as a handful of pieces.

Fermér said the floor is “a good starting point” because “it’s fairly easy to design a safe and robust rear floor. You have a lot of complicated interfaces that you replace when you go from 100 parts to one”.

He added that “it’s your imagination” that limits what can be done with mega-casting, but said: “It should always be based on the business case and function. We have looked into casting a complete battery tray, which makes sense because it could replace many parts.”