Nissan has officially commenced production of the third-generation LEAF at its Sunderland Plant in the United Kingdom. This event marks the operational launch of the automaker’s EV36Zero strategy, a manufacturing ecosystem integrating electric vehicle production with battery manufacturing and renewable energy.
Highlights
- £450 million investment upgrades facilities for next-gen EV production.
- Factory integration includes a new AESC gigafactory for battery supply.
- Production Line Two adapted for EV manufacturing with advanced automation.
- New LEAF specifications feature a 386-mile range and 150kW fast charging.
Facility Transformation and Investment
The production launch follows a £450 million investment aimed at modernizing the Sunderland facility and its supply chain. This capital project enables the manufacturing of electric vehicles on production Line Two for the first time. The initiative is part of a broader strategy to anchor a competitive EV supply chain within the region.
To accommodate the new platform, the plant integrated “factory of the future” technologies. These upgrades utilize big data, digital mapping, and virtual reality to optimize assembly processes.
Key infrastructure upgrades include:
- 137 new press dies in the Press and Plastics Shop to mold the vehicle’s 42 distinct body panels.
- 78 high-tech robots installed in the Body Shop, featuring a fully automated laser welding facility capable of 0.3mm precision.
- Automated battery marriage technology that secures the battery pack to the chassis, fastening 26 bolts in 56 seconds.
- 475 automated guided vehicles (AGVs) utilized for parts logistics directly to the production line.
- New paint shop capabilities introduced to accommodate updated color palettes.
Supply Chain and Battery Technology
A critical component of the EV36Zero model is the proximity of the supply chain. The new LEAF utilizes next-generation battery technology supplied by the AESC gigafactory located adjacent to the assembly plant.
This facility provides batteries with increased energy density compared to previous generations. The proximity of the gigafactory is intended to increase logistics efficiency and support high-volume production.
Vehicle Specifications and Performance
The first unit off the production line was a Luminous Teal Evolve grade. The third-generation LEAF offers updated performance metrics designed to compete in the current C-segment EV market.
Technical specifications include:
- Battery Capacity: 75kW.
- Range: Up to 386 miles (WLTP cycle).
- Charging: Supports 150kW DC fast charging.
- Charge Time: Adds approximately 273 miles of range in 30 minutes.
The vehicle interior integrates a fully digital cockpit featuring twin 14.3-inch screens. The infotainment system runs on Google built-in, providing native access to navigation and connected services.
Future Production Outlook
The Sunderland Plant currently employs 6,000 staff, with a total of 7,000 across Nissan’s UK operations. The facility has produced over 282,000 LEAF units since 2013.
Looking forward, the plant is scheduled to begin production of an all-electric Nissan JUKE in the coming year. Both the LEAF and the future JUKE will be manufactured on Line Two. This allows the facility to produce a mix of powertrains, including fully electric, e-POWER, hybrid, and internal combustion engines on the same line.
https://www.nissan-global.com/EN
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