Range Rover’s Hidden Mid-Size EV: Tour of £500M Plant

Jaguar Land Rover is revolutionizing its production capabilities with a massive £500 million upgrade to its Halewood facility in Liverpool, setting the stage for an exciting new mid-size electric Range Rover. This vehicle, comparable in stature to the current Velar but engineered for zero-emissions performance, marks a pivotal shift toward electrification in luxury SUVs.

The Birth of a New Electric Era at Halewood

Halewood, long a cornerstone of JLR’s manufacturing, is undergoing a profound metamorphosis into a state-of-the-art digital factory. The investment, rolled out in phases, focuses on introducing the Electric Modular Architecture (EMA) platform, a flexible system designed specifically for battery-electric vehicles. Planning for this transition kicked off four years ago, aligning with global demands for sustainable mobility.

The facility’s new body shop represents the crown jewel of this overhaul. Equipped with cutting-edge robotics and automation, it will assemble the skateboard chassis unique to this EV, ensuring precision and efficiency. Workers and engineers now operate in an environment blending human expertise with AI-driven processes, minimizing errors and maximizing output.

Vehicle Profile: Size, Design, and Powertrain Innovations

Sized similarly to the Range Rover Velar, this upcoming EV distinguishes itself with a **longer wheelbase** and **lower roofline**, optimizing aerodynamics and interior space for luxury. Its coupe-like SUV silhouette hints at a sportier aesthetic, positioning it as a direct competitor to the Porsche Macan Electric.

Under the skin, dual electric motors—one at each axle—deliver a combined **542 horsepower**, enabling thrilling acceleration while maintaining the Range Rover’s legendary off-road dominance. A **118kWh battery** integrates as a stressed member in the chassis, enhancing structural rigidity and making it the strongest Range Rover ever. This setup supports an 800-volt architecture for rapid charging, potentially adding significant range in under 30 minutes at compatible stations.

Factory Transformation: From Assembly Lines to EV Precision

The £500 million infusion isn’t just about new machinery; it’s a holistic upgrade. Traditional stamping and welding areas have evolved into flexible zones capable of handling aluminum-intensive bodies for both EVs and hybrids. Advanced vision systems and laser-guided robots ensure tolerances down to millimeters, crucial for battery integration and crash safety.

• Body-in-White Assembly: New lines for EMA chassis, using over 100 robots for spot welding and adhesive bonding.
• Paint Shop Upgrades: Eco-friendly water-based paints and AI quality checks for flawless finishes.
• Final Assembly: Seamless integration of powertrains, with dedicated EV battery marriage stations.

This setup allows Halewood to produce multiple models on shared lines, boosting efficiency amid rising EV demand. Over 48,000 clients are already waitlisted for Range Rover EVs, underscoring market anticipation.

Performance and Off-Road Prowess Redefined

Prototypes have undergone rigorous testing, including Nürburgring laps and arctic winters, proving the EV’s mettle. Twin motors provide torque vectoring for superior traction on mud, snow, or rocks—hallmarks of Range Rover DNA. Expect **individual wheel control** akin to advanced systems in rivals, with silent propulsion enhancing refinement.

The 117-118kWh pack, featuring prismatic cells, balances weight distribution for agile handling. Off-road, air suspension and adaptive dynamics will adjust clearance up to 11 inches, while on-road, it promises a serene cabin with active noise cancellation.

Strategic Importance in JLR’s Electrification Roadmap

JLR’s CEO Adrian Mardell has outlined a clear path: MLA-based BEVs first, followed by EMA models like this mid-size SUV in spring 2026. Replacing the Velar, it targets buyers seeking luxury without compromise. Halewood’s role extends beyond this model, positioning JLR for annual EV volumes exceeding 100,000 units.

Sustainability drives the project—recycled materials in interiors, low-carbon aluminum, and energy-efficient factory operations align with net-zero goals by 2040.

Comparing to Flagship Range Rover EV

While the full-size Range Rover EV on MLA Flex boasts similar 550hp and 117kWh batteries, the mid-size variant prioritizes agility. Both share premium features like 35-inch screens and Meridian audio, but the EMA platform enables cost efficiencies for broader appeal.

Market Positioning and Rivals

This EV challenges Porsche Macan Electric with stylish design and superior off-road chops. BMW iX3 and Mercedes EQE SUV enter the fray, but none match Range Rover’s terrain mastery. Pricing likely starts above £80,000, justified by bespoke engineering.

Inside the Factory: Daily Operations and Workforce

Our virtual tour reveals a buzzing hive: engineers calibrating battery packs, technicians testing high-voltage systems, and quality auditors scanning for imperfections. Training programs upskill 2,000+ employees in EV tech, fostering pride in building the future.

Safety protocols are paramount—isolated EV zones prevent arc flash risks, with automated guided vehicles shuttling parts seamlessly.

Future Prospects and Industry Impact

Beyond 2026, EMA will underpin more JLR EVs, including Jaguar models. Halewood’s success could inspire UK manufacturing revival, creating jobs and supply chain ripples. With prototypes shocking testers via winter prowess and silent power, expectations soar.

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