Revving Towards the Future: Honda’s 0 Series Prototype Promises a Nimble and Efficient EV Revolution

During a recent visit to Honda's research and development center in Tochigi, Japan, I had the opportunity to witness firsthand the extensive engineering efforts to transition Honda vehicles to electric power. This culminated in a thrilling, approximately 10-minute test drive of a camouflaged 0 Series electric vehicle (EV).

It provided a solution to a puzzle that constantly occupied my thoughts: How is it possible for a vehicle with the sleek and sporty appearance of the Honda Saloon concept to possess a design that's almost ready for manufacturing?

Unveiling of the Honda Sedan Prototype at the

At the CES event in January, Honda unveiled two concept vehicles, the Space-Hub and Saloon EV. Notably, the Saloon EV, with its supercar-inspired kammback design, garnered significant attention. Honda officials even suggested that this model's striking appearance is close to being ready for manufacture.

It highlights a significant issue: Developing advanced, market-ready battery and drive systems isn't the sole obstacle traditional car manufacturers encounter as they transition to electric vehicles. Potentially, the bigger hurdle is designing the vehicle's remaining components, or the "top hat" as it's known in the trade, to integrate with these systems.

Honda's Electric Vehicle Framework for the 0

Platform for Electric Vehicles from the Honda 0

Honda's Electric Vehicle Platform known as the

Honda asserts it is equipped to tackle the challenge of creating a vehicle design that meets stringent crash-test norms, accommodates spacious interiors for passengers, and diverges from the conventional electric vehicle configurations. This vehicle is the embodiment of Honda's newfound "slim, lightweight, and smart" approach to the design of its imminent 0 Series electric vehicles. These vehicles represent a new chapter for Honda as it moves beyond its initial Prologue model, which was developed in collaboration with GM, and transitions to its very own line of mass-produced EVs engineered by Honda. Production for this series is set to commence in Ohio towards the end of 2025.

The initial pair of electric vehicles to hit the market will include an Acura SUV, initially introduced through the Performance EV concept in August, followed by a model ready for production based on the Saloon concept.

Honda may not be fully prepared to unveil its sleek new design in its final form, but it is prepared to share an insight into all the development that's been happening behind the scenes.

During CES, the car manufacturer shared extensive details on the characteristics of the Honda 0 Series electric vehicles, highlighting that they will not resemble existing models like the Accord, Civic, CR-V, or any specialized vehicles. Essentially, Honda intends to create a clear distinction between its electric vehicles and its other offerings, which include gasoline-powered vehicles, hybrids, and potentially plug-in hybrids. The company aims to keep its electric vehicle architecture, excluding the electronics platform and user interface, separate from its gasoline and hybrid models.

Prototype of the Honda 0 Series platform (Accord model)

Interestingly enough, I found myself ready to take control of several major components of Honda's 0 Series framework, whether it be in an Accord or a CR-V. This included managing the base structure and battery housing, along with the 0 Series' suspension system. Each model underwent adjustments to their suspension and propulsion mechanisms to suit their specific weight balances. However, I made a beeline for the Accord following a hint that it might offer the most representative experience of the 0 Series' handling characteristics.

Honda is redefining the foundation for electric vehicles, moving away from the "thick and heavy" stereotype. The company is focusing on "thin, light, and smart" designs to overcome the limitations associated with the traditional bulky electric vehicle. The typical EV design, with its large battery packs, hefty cooling mechanisms, and robust body frames that try to serve both sedans and SUVs, often results in a compromise that fails to efficiently accommodate the needs at either end of the spectrum.

The Honda Saloon concept features dynamic aerodynamic elements and a sleek design, ensuring it surpasses all other production cars in terms of air resistance. Additionally, it aims to maintain a total height under 55 inches, without sacrificing ample cabin room for adult passengers.

The process began with the design of a slender and extremely low-profile battery pack that serves as a foundational element. By integrating compact electric axles and a body structure that primarily uses aluminum, the vehicle's weight is centralized. Honda has shortened the protruding parts of the car and has reconceptualized how the body's flexibility at the front and back interacts with the suspension system, opting for reduced side-to-side stiffness compared to what's typical in today's vehicles. According to Honda, this reduction in weight contributes to a more agile driving experience.

Honda's Electric Vehicle Architecture for the 0

The power pack serves as a component of the Integrated Power Unit, which not only functions as a housing for the battery but also plays a crucial role in the vehicle's framework. This unit is reinforced with sturdy beams that, in conjunction with the pack, contribute to the vehicle's structural integrity and increase protection against side collisions.

The sleek hoodline and aerodynamic design are enabled by an underlying body structure not designed for front-mounted engines. The frontal impact force is distributed to the sturdy side rails, eliminating the necessity for taller structural crossmembers across the hood area.

All models within the Honda 0 Series will feature either all-wheel drive or rear-wheel drive capabilities. Up to this point, Honda has developed an electric drive unit with a power output of 180-kw (241-hp) and another unit with 50-kw (67-hp), the latter being utilized in their dual-mode hybrid vehicles. Honda claims that their e-Axle technology is 40% more compact when compared to the average size of similar components provided by competitor's original equipment manufacturers. While Honda considers these e-axles to be exclusive to their brand, they are actually produced by Hitachi Astemo, a company in which Honda holds a controlling interest.

Honda's Electric Sedan Design Concept

Conceptual Electric Sedan by Honda

Concept model of an electric vehicle by Honda designed

Honda is targeting a 300-mile range

Honda has set a goal to reach approximately a 300-mile driving range for different models within the 0 Series, as per the EPA's testing cycle. This will be accomplished by adjusting the sizes of the battery packs. Honda claims that the 0 Series models are more efficient in their heating power consumption by 13% due to the inclusion of a radiant heater and heat pump. This efficiency also leads to less range reduction in cold weather compared to competing vehicles.

Honda has assured that the 0 Series will outperform its competitors by 2% in terms of energy efficiency. This is measured by the distance the vehicle can travel per unit of energy. However, without concrete comparisons to specific brands such as Tesla and Lucid, it's challenging to predict Honda's exact positioning.

The Honda Accord model I tested was equipped with a pair of engines, each capable of 241 horsepower, which could potentially combine for over 480 horsepower. However, Honda representatives did not verify if the engines were performing at their maximum capacity. There's been no word from Honda on fundamental details such as the size of the battery. However, they did share that the battery cells will be exclusively pouch-type, provided through a partnership with LG. Honda has yet to release any numbers regarding the charging speed or state whether these electric vehicles will be compatible with 400 or 800-volt systems. They have, however, indicated that future iterations of the 0 Series expected in the coming years will be able to recharge from 15% to 80% within 10-15 minutes, hinting at the possibility of 800-volt charging capabilities. Moreover, these models are anticipated to retain at least 90% battery capacity even after a decade of usage.

The vehicles in question will receive their battery cells through a partnership with LG, which will be distributed through a collaborative effort between LG and Honda based in Ohio. Although Honda has not specified the number of cells contained in each module, it has been confirmed that their battery management system operates on a wired basis and keeps track of resistance at the individual cell level.

Prototype platform for Honda's 0 Series (Accord model)

Halvorson engages in conversation about the Series 0's performance features with the lead engineer.

The Honda Accord will feature the new 0 Series electric vehicle platform

Test Drive of Honda 0 Series Early Model

Returning to the initial impressions: The vehicle I'm experiencing seems at first glance to be an Accord, equipped with some experimental gadgets and a slim monitor, which bears no resemblance to the expansive display found in the Saloon prototype. However, I've been informed that certain elements of this prototype are nearly identical to the final version of the 0 Series.

Emerging from the starting point onto the straightaway of the compact race track, I gradually press down on the gas pedal, fully engaging it for a brief moment before carefully navigating the track's bends. It becomes apparent quite swiftly that despite its larger weight, this electric vehicle handles with greater agility and stability compared to a standard Accord. After receiving an encouraging signal from the development engineer riding alongside me, I accelerate slightly beyond the anticipated speeds for this drill, ultimately hitting close to 75 mph. Impressively, the vehicle's drive system maintains a low noise level even at that speed.

Prototype of Honda's Series 0 (Accord model)

In general, this matches the speed of the fastest all-wheel drive electric vehicles out there, with the exception of those sporting Plaid, Performance, or N logos. Additionally, the motors provide their power smoothly without any shakiness, and they seem to work harmoniously with the stability and body control systems.

The prototype of the 0 Series, which is built on the Accord framework, lacks the steer-by-wire system set for the final version. The braking setup in this model isn't what will be seen in the end product, and it features just a single, moderate brake regeneration setting that slightly reduces speed but still necessitates the use of the brake pedal. Honda has not disclosed the energy capacity of the prototype's battery, nor if its weight is similar to the anticipated production model, or the extent to which it surpasses the weight of an Accord running on petrol. However, it was verified that the prototype does weigh more than its gasoline-powered Accord counterpart.

Prototype of the Honda Series 0 (Accord Model)

The prototype of the 0 Series outperforms the Accord in terms of handling. It's equipped with the 0 Series' pneumatic suspension system, featuring air-spring struts at the front and a multi-link arrangement with air springs at the rear. Additionally, it incorporates the 0 Series' stability and body control systems, which make use of 3D gyro sensors originally developed for Honda's ASIMO robots, marking a global innovation as claimed by Honda.

From my perspective, it appears to be an Accord with a more stable turn and a lower stance. However, the engineer accompanying me pointed out that the seating position in this vehicle is, in fact, a tad higher compared to a regular Accord.

Following my turn behind the wheel, I took a step back to observe this unique Accord during its next round on the track, and indeed, from the outside, it visibly maintained a level stance through the turns, just as it had seemed from

I gained a deeper understanding of Honda's innovative approach to producing these electric vehicles after distancing myself from the prototype. Impressively, the casing for the battery pack is the most substantial single casting Honda has ever created, even more so than its engines. This casing consists of merely five components, a stark contrast to the 60 or more found in others, according to Honda. To construct these, the company will be utilizing six massive 6,000-ton machines capable of high-pressure die-casting at its Ohio plants. This 'megacasting' method is preferred because it consumes less energy compared to 'gigacasting' and offers more versatility in production.

Honda's 0 Series framework – energy storage unit

Additionally, following a rapid robotic trimming procedure, a method known as friction stir welding will be employed to join the components of the pack, ensuring accurately formed cooling channels. Everything seems set for the escalation of mass production.

Honda is gearing up for a semi-automated flexible manufacturing setup, enabling swift adjustments to the variety of battery pack dimensions in response to car sales trends. Honda predicts that about three-quarters of the 0 Series electric vehicles will require medium-sized batteries, with the remaining 25% needing larger ones.

Production of 0 Series to take place in Ohio, together with traditional gasoline cars

This highlights a key detail: The production of the 0 Series electric vehicles is designed in such a way that they can be constructed alongside Honda's conventional internal combustion engine vehicles within a partially automated production line in Ohio.

Honda has ambitions to significantly scale up the production of sizable aluminum modules for the rear sections of its 0 Series electric vehicles, potentially kicking off this initiative in its Canadian facility around 2028. Moreover, the company is implementing a unique welding technology known as CDC (constant direct current chopping) tailored for this particular frame and metal composition, which results in more robust welds while consuming less energy.

Platform Series 0 by Honda

The 0 Series is set to operate using Honda's latest electrical and electronic framework, which is divided into three main electronic control units (ECUs): the first handling safety and self-driving capabilities; the second managing vehicle dynamics, body electronics, and power control; and the third dedicated to the digital user experience. They are also looking to introduce a sophisticated vehicle calling function and an extended-reality (XR) option that enables virtual companionship from friends or family during the drive.

Honda is set to incorporate advanced detection capabilities through the use of lidar technology, the combination of multiple sensors for enhanced long-distance and nocturnal detection, and their unique artificial intelligence. The company aims to introduce Level 3 autonomous driving capabilities. This system is designed to operate beyond just pre-mapped routes. Honda claims that, as the 0 Series progresses, this system will become the quickest globally for fully autonomous operation without the need for driver observation.

Securing an electric four-door car with a genuinely agile and ground-hugging sensation continues to be difficult. However, Honda is confident it can deliver a sleek, elongated, and expansive vehicle along with two SUVs by 2026, followed by a larger SUV with three rows of seating in 2027, additional SUV models rolling out in 2028 and 2029, and a smaller four-door electric model by 2030, all built on the 0 Series electric platform.

Should it succeed in propelling these forward, proving that the underlying elements aren't the constraint, that would be an impressive beginning.

Green Car Reports received several amenities such as lodging and dining to aid in the creation of this article.

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