The Volt platform

Curiously, the beast was sleeping not very far. "I'd like to tell you that we have developed the E-Flex for a very long time, but that's not what happened, says Bob Lutz. Actually, we've been working for several years on different types of programs: electric motors, fuel cells..."

"And all of a sudden, it was like we took a step back to get a general perspective," adds Nicholas Zielinski, Vehicle Chief Engineer, Advanced Systems Integration.

From that point on, everything fell into place like the pieces of a puzzle. GM focused on their most promising technologies, such as the electric drive system of the Chevrolet Equinox Fuel Cell and the global compact platform of the Cobalt/Astra -- the perfect architecture for an urban application like the Volt.

And thus, the E-Flex was born.

"I call it the 'Perfect Storm'!," says Zielinski with a laugh.

400 recycled bottles

The Volt's door panels are made from recycled plastic.

The Volt allowed GM to explore further. A partnership with General Electric's Plastic division resulted in composite body panels that use 400 recycled water bottles and that prove to be up to 50 percent lighter than steel.

Consequently, the concept weighs less than 1,500 kilos, which is the equivalent of a Chevrolet HHR. That's not bad, especially considering that the batteries alone weigh 181 kilos...

Too good to be true?
Too good to be true? For now, yes.

GM confessed that the technology is not ready yet. The biggest challenge? The batteries.

The lithium batteries in the Volt "currently offer a range of 15 to 25 kilometers, but we're asking our suppliers to achieve a range of 64 kilometers," says Larry Burns, Vice-President, Research & Development and Planning, General Motors.

Also, the automaker must ensure that the batteries don't produce

Bob Lutz, during the launch of the Chevrolet Volt at the NAIAS.

excessive heat; otherwise, a cooling system will have to be designed. Finally, GM wants the batteries to last 10 years (about 4,000 recharges).

How long before these breakthroughs happen? What if they can't be achieved? "By my calculation, we're facing a 10 percent chance of failure," admits Mr. Lutz.

One thing's for sure, though: "We would not make these major R&D investments if we were not confident to succeed," concludes GM's vice-president.