Solar cars

September 20, 2025

Is it a car, a UFO or…? Part 2:  Inside Aptera’s Innovative Production Facility

By Jeff Daum, Ph.D., PPA

Product & Technology Analyst

Those of you who follow my blog might recall that I ended my initial article on Aptera Motors Corp.1 saying “This is hopefully Part 1 of a multipart Aptera review.  Stay tuned for Part 2: a factory visit and first drive…”  I just returned from Aptera’s production facility and while I did not get the opportunity to drive the Aptera, I did enjoy a ride in a preproduction unit.

My focus here will be on what I’ve learned and not to go over the points discussed in my initial article (link in footnote) other than to reiterate my full transparency statement: I was so impressed with the Aptera, its cutting-edge technology and dual CEO team direction and commitment, that I have placed and received confirmation of a pre order future variant all-wheel drive Aptera.

Our tour- my wife accompanied me being highly curious about the Aptera and why I was excited about it- was facilitated by Will Jarrett from Aptera’s Marketing department.  Aptera Motors intended production facility in Carlsbad California is a bright open space building of approximately 77,000 square feet.

While the formal visitor tour set up is still being developed, parts of it are currently in place including:

  • A preproduction version with the same body shape as the production version, but with a clear glass rear hatch instead of solar panels
  • The front-end light unit from the supplier with its classic smile look
  • A complete body shell
  • A full frame
  • An AGV robot of the type that will be used to automatically move the assembly components around the production line
  • Various solar panels for different sections of the Aptera, all designed and made in-house
  • An earlier version Aptera in striking matt black
  • Gold colored Gamma version
  • More solar panels including those being sold to other companies for non-Aptera applications
  • A pneumatic ‘gun’ for firing pellets at the solar panels for testing durability
  • Aptera bodies with nearly complete interior components
  • A video simulation showing the 14 or so stations that the assembly line will progress through on the AGVs

Not included in the tour were areas of the facility that housed testing rooms, subassembly rooms, etc.

As we walked through the facility, Will explained what we were looking at and responded to my questions.  Here is a summary of our discussions.  The extremely low coefficient of drag body is manufactured in Modena Italy by the C.P.C. Group and is a combination of Carbon Fiber Sheet Molding Compound and Glass Sheet Molding Compound and shipped over as a unit.  Amongst its advantages are the significant strength to low weight ratio and that it has only six structural pieces compared to the hundreds that are used in most cars.  The Aptera safety cage is modeled after Formula 1 cars!

It sits on a custom metallic chassis that is also made in Italy by the Costamp Group, located right next to C.P.C.

The components and Apteras as they are being assembled will be moved around the 14 stations of the production line on AGVs that follow the blue line that can be seen on the facility floor.  The advantage of this AGV technology is flexibility over fixed production lines.  If something happens with one of the AGVs it can be pushed aside and the line will continue to operate.

The cars will be primarily assembled by people, assisted by automation where practical.  After the low-volume production phase, the objective is to produce 20,000 Apteras in this facility per year.

[above three images are screen shots from Aptera’s Media Simulated Production Line video]

The battery assembly will be done in house.  40 KWh unit will provide a 400-mile range.  They will be using LG batteries.

The solar panels are designed and patented by Aptera’s team.  They have also started licensing the technology to others for alternative applications.  Amazingly they are bendable and have a glass surface similar to Gorilla Glass (as used in smartphones).  They can withstand direct hits without breaking.  The design allows for the panels to be replaced if necessary postproduction.  For example, if a section gets damaged, or down the road the efficiency of the solar panels improves so much that it might make sense to swap the older ones out.

The production versions will have a solid trunk lid without glass and be covered with solar panels and use a camera for an unobstructed comprehensive rear view in a center mounted electronic rear view mirror (similar to the one used in the new Corvette for example).  The side mirrors are combination of mirrors and cameras. The mirrors are required to follow existing US NHTSA law.  The cameras show clear views of both sides of the Aptera on two screens directly behind the steering wheel.

The gold unit “Gamma” in the following image is the most recent prototype, though they now have Production Validation versions.  This is the one we rode in.

The silver unit is a current Production Validation Aptera called Artemis and is the one that they did the extended Route 66 trip.

There are a few additional things that Will pointed out.  They have built-in fail-safe backups like having buttons behind the large central screen that will allow you to continue to drive the Aptera if the screen fails.

The trunk lid is designed to open part way without flying up so that if you have a low ceiling you don’t have to worry about it hitting it.  You manually open the lid the rest of the way.

There are plans to have several options for the battery pack beyond the standard 400-mile range, including a 250-mile range, 600-mile range and 1000-mile range.  Also having a Level 2 Autonomous driving option.

In the image above, you can see the North American Charging Standard (NACS) port located behind the license plate which slides to the side providing access

While Will is not permitted to discuss the status of funding he said once sufficient capital is obtained it will be about nine months until the first production vehicles are finished and out the door.

My thoughts following the tour and ride

Having driven several all-electric vehicles from different OEMs and currently owning one, I’ve come to expect lots of torque and rapid acceleration from an EV and Aptera doesn’t disappoint.  What I did not expect was that Aptera, a three-wheeler, would feel so rock solid through turns at speed.

The interior is roomy and comfortable, feeling for example very comparable to my Corvette Stingray Coupe (but Aptera has more headroom) with a surprising amount of usable space behind the seats. 

Visibility looking out is very good and supplemented by an electronic rearview central mirror as well as electronic side views on two screens directly in the driver line of sight.

Aptera has lots of ‘coolness factors’ including its slipstream shape, knock on the body to open doors and trunk (no outside handles) and the solar recharging.

I am left with two concerns at this point:  One is a driving practicality issue and the other is whether Aptera will achieve financial fluidity to realize their objectives.

What I mean by driving practicality comes down to how the two “outrigger” front wheel units will survive in real world situations.  They are quite wide at approximately 88” across when the wheels are straight and wider when turned off center.  This width is further compounded by the fact that the tops of the wheel units are low with respect to the Aptera body.  That wheel unit to wheel unit width is greater than many cars and even small trucks on the road today.

Here is why I think this may be a concern: If you backed your Aptera in the center of a typical parking spot in a parking garage, the slot often is only 9 feet or less wide, which leaves about 10 inches or less between the edge of your wheel unit and the edge of the next parking slot.  If a car, or worse a truck, then goes to back in next to you and turns in rather than pulling straight in, what are the odds that they will only glance at the body of your Aptera and not see the outrigger front wheels?  Since the Aptera front wheels contain also the driving motors if they get brushed or hit the damage could be considerable.  Will the wheel units need some sort of pop-up flag or indicator to ensure they are seen and avoided when parked?

This width will also require drivers to maintain better vigilance regarding staying in the center of their lane and not straying on the road compared to driving other vehicles.

Regarding Aptera Motors Corp. viability I did some research on their current financial Issues.  Based on Aptera’s August 27, 2025, Form S-1 filing for listing on NASDAQ here is their estimate of funding still needed for production: “Our production plan for our Carlsbad facility is phased and each phase is contingent upon a specific level of funding. The initial “low-volume” production phase is estimated to require approximately $65 million in capital to fund remaining necessary tooling and validation programs. Following the initiation of low-volume production, a second phase to ramp to high-volume production would require an estimated additional $140-$160 million. This high-volume rate, which we project to be approximately 20,000 vehicles per year at our current facility’s maximum capacity, was a figure determined in consultation with Munro & Associates, a firm specializing in lean manufacturing principles for the automotive industry.”

“Specifically, securing the capital estimated for both initial low-volume and subsequent high-volume production phases is critical. Until this funding is secured, the Company will be unable to predict if and when production will commence.”

Hopefully the listing on NASDAQ and subsequent offers will go well (and rapidly) for Aptera- I am so looking forward to having one in my garage!

P.S., My wife really enjoyed her ride and was impressed with the Aptera 😊.

Marques Brownlee has just posted an informative video based on his driving a preproduction Aptera. You can view it at https://www.youtube.com/watch?v=2OvyyVxQjuI He raises some excellent points.

Stay tuned for my next Aptera update! Thanks for visiting and reading. If you have a question or comment, please feel free to enter it below!

  1. https://insight.daumphotography.com/2025/01/19/is-it-a-car-a-ufo-or-first-look-at-the-aptera-the-future-of-electric-solar-vehicles/ ↩︎

January 19, 2025

Is it a car, a UFO or…? First look at the Aptera: The Future of Electric Solar Vehicles

By Jeff Daum, Ph.D., PPA

This is an initial look at the Aptera all electric solar vehicle presented at the 2025 CES (Consumer Electronics Show) in Las Vegas, Nevada. 

Let me begin with a full transparency statement: I was so impressed with the Aptera, its cutting-edge technology and dual CEO team direction and commitment, that I have placed and received confirmation of a pre-order future variant all-wheel drive Aptera.

The first thing that you notice is its unique aerodynamic shape.  In fact, because of this shape it has the lowest coefficient of drag of any road vehicle at approximately 0.15!  The body was designed in concert with Pininfarina and is out of carbon fiber.  It is manufactured in Italy and shipped to Aptera Motors facilities in Carlsbad, California.

Probably the next thing you will notice is that Aptera has two front wheels and one rear wheel- an autocycle.  It is classified by the DMV as a motorcycle, specifically a Trike with full enclosure.  This means that it is registered as a motorcycle but you will not need a motorcycle driver’s license nor need a helmet.

Like most sports cars, the interior includes side-by-side two passenger seating.  It has all the normal accouterments: safety belts, frontal driver and passenger air bags, a steering wheel, accelerator and brake pedals, ac and heat, etc.  In front of the steering wheel is a horizontal screen that continually shows full views of the right and left side of the Aptera virtually eliminating any blind spots.  To the right of the steering wheel is the infotainment and information display.  The electronic rearview mirror shows the unobstructed view behind the Aptera (from a camera on the roof).  There is also a backup camera located adjacent to the license plate.  The plate holder slides to the side, revealing the NACS charging receptor.

Aptera has bespoke solar cells on the hood, dash and roof capable of generating 700 watts of electricity.  Each cell is incredibly thin, lightweight and glass covered yet capable of being bent to conform to the respective body shape.  According to their website details, an individual cell could be cracked yet continue to generate power because of its unique wiring. 

While I was at CES, one of the two Production Intent Vehicles was driven for 25 miles on the streets around Las Vegas.  The solar cells generated and put back into the batteries the equivalent of 29 miles of electricity!  Wait, what? Yes, it generated more power than it used.  Of course it can be plugged in to recharge its batteries. Plugging into a regular 110-volt outlet will put approximately 150 miles of energy into the batteries overnight.  It can also use Level 2 chargers which will put approximately 60 miles of energy into the batteries per hour or a DC fast charger can put approximately 500 miles of energy into the batteries in an hour.  The Aptera recharges in about one fourth of the time of other EVs.

According to Aptera’s website, “the Launch Edition uses 21700 NMC 811 cylindrical lithium-ion cells, known for their high energy density and long life. The 44 kWh battery pack contains 2,304 cells, delivering 400 miles of range.” [ https://aptera.us/article/what-batteries-are-inside-aptera/ ]

I had the pleasure of talking with Chris Anthony, Founder and CEO Aptera Motors.

Chris image courtesy of Aptera

  Chris’ partner, Steve Fabro, also carries the title of Founder and CEO.

Steve, image courtesy of Aptera

I started off asking Chris about Aptera’s design elements to ensure safety, Here are highlights from this interview:

  • Regarding Aptera’s safety: Able to do things with carbon fiber that steel and aluminum vehicles can’t do.  Able to add protection such as great frontal impact strategies, offset frontal, side impact.  Crash energy is diverted from the passenger area downwards to the well protected battery and frame.  Aptera has front and rear crumple zones. Aptera has front and rear crumple zones and a carbon fiber roll bar.
  • Suspension dynamics: even though it is a three-wheel vehicle, because the heavy battery is mounted so low, it has almost the exact same suspension dynamics as a VW Golf.
  • Done lots of track testing and skid pad stuff, curb strike angles at forty-five miles per hour, pothole tests every which way you can think of with the vehicle, and because the battery weight is so low it is extremely stable.
  • We will be running Crash Tests shortly.
  • It has better ground clearance than a Honda Civic with six inches to the belly and five and one-quarter inches to the wheel pans, and ingress and egress a couple of degrees better than the Honda Civic.
  • Regarding stability, especially with the large area by the rear wheel, it has a low-profile mid-section.   We have simulated cross winds up to 115 mph and it performs better than other vehicles because flat sided vehicles are much more susceptible to the winds.  There is no float created because it is basically a downforce vehicle that creates a bit of downforce, though we attempted to keep it as neutral as possible.
  • The tires are 195-55 R16 low rolling resistance, specially formulated for them by Hankook Tires.
  • The ABS and airbags (passenger and driver frontal airbags) are currently undergoing calibration.
  • It has DC Fast Charge, Level 2 and regular 110 outlet capability.  The 110-volt outlet will provide 150 miles charge overnight.  The Aptera uses one quarter the energy of the average EV, meaning we charge four times faster.  A DC Fast Charger will put 500 miles an hour into it, a Level 2 will put 60 miles per hour and a regular outlet will put 13 miles an hour into it.
  • Currently we have more than 50,000 preorders from across 115 countries, had the largest Crowd Funding in the industry with 20,000 individual investors, and now working on an IPO and hope to have production vehicles in people’s hands by the end of the year.
  • No dealerships, but have distribution centers around the world, and working with some Tribal communities in states that don’t like the lack of dealerships similar to what Tesla does.
  • In sum, the Aptiva is much more akin to a formula one car than anything else on the road. It is the penultimate in aerodynamic efficiency and has a carbon fiber chassis through and through.  It is an interesting mix to try an be the most efficient vehicle in the world but also have really extreme performance, when you look at the how the vehicle is constructed and how we achieve 100-watt hours per mile and still keep safety paramount, and get all the solar power out of it we need. The Aptera is the most efficient vehicle in the world but still sporty and very nimble.

Some addition information from the Aptera website https://aptera.us/  :

  • the core of our design is a safety cell crafted from Carbon Fiber Sheet Molding Compound (CF-SMC), which is both ultra-lightweight and stronger than steel, paired with metallic subframes that absorb impact energy.
  • Aptera’s body features a specialized composite structure known as Body in Carbon (BinC), primarily constructed from Carbon Fiber Sheet Molding Compound (CF-SMC) and Glass Sheet Molding Compound (SMC). CF-SMC is a lightweight material that utilizes a random arrangement of short fibers, allowing for the creation of intricately shaped parts with significantly higher stiffness and strength compared to standard SMC.
  • Aptera features an unequal-length dual wishbone suspension in the front and a double trailing link suspension in the rear. This advanced suspension system provides a balanced combination of stability, control, and ride comfort, allowing for smooth handling across diverse terrains.
  • The largest single component is the carbon fiber tub.
  • Use of SMC side panels on the body that won’t dent when hit.
  • Front wheel covers rotate up to allow access to tire valve stem and rear tire has a small access hole for the same purpose.
  • At Aptera, we’re redefining the repair experience by making it accessible, straightforward, and affordable. Whether you’re repairing your vehicle yourself or working with a local shop, Aptera will provide detailed documentation and make spare parts easy to order. Unlike typical processes where maintenance information and parts access can be limited, we believe in empowering owners with everything they need to keep their vehicles in top condition.
  • The Launch Edition’s dimensions are optimized for aerodynamics and stability. The vehicle measures 15 feet (4.56 m) in length, 7.3 feet (2.22 meters) in width, and stands 4.6 feet (1.4 meters) high, with a wheelbase of 9.2 feet (2.82 meters).
  • Aptera has integrated the Vitesco Technologies’ EMR3 drivetrain—a high-voltage axle drive that combines a permanent-magnet synchronous e-motor, inverter, and reducer in one compact unit. 

Final thoughts:

I had a chance to sit in the Production Intent Aptera and found the seats very comfortable.  The interior is airy with great outward visibility.  The ‘double knock’ to open the door or trunk is a fun twist- there are no outside door handles.  The trunk is quite spacious, easily carrying two regular golf bags or even, apparently, with the seats folded forward, room to lie down if you take the Aptera camping.  There is also a small compartment under the regular rear floor that can be used to store charging cables or other supplies.

I am particularly impressed with Chris and Steve’s vision and approach.  They are continually striving to use their own and their team’s knowledge, seek and use outstanding third party input and resources, and harness AI to refine the Aptera to be highly efficient, practical and fun.  The use of Open-Source Software and Right To Repair sets the Aptera apart.

Of course, the ‘elephant in the room’ question, unanswered at this point is whether Aptera will make it where many others have failed.  Their concept appears sound, the technology is there, Production Intent Vehicles validated, but the financial green light is still pending.  According to Scooter Doll writing for electrek on Nov 5, 2024: “Last we heard, Aptera had raised over $135 million from over 17,000 investors, which the startup touted as the most successful crowdfunding raise in history. However, the company shared that it would need another $60 million in additional funding to begin low-volume SEV production, now slotted for late 2025.”

This is hopefully Part 1 of a multipart Aptera review.  Stay tuned for Part 2: a factory visit and first drive…

Thanks for visiting and reading. What are your thoughts on the Aptera? If you have a question or comment, please feel free to enter it below!