How Volvo’s ES90 sets New Standards in Sustainable Design

Volvo Cars' (Volvo) fully electric ES90 model is produced with climate-neutral energy and designed with sustainability in mind. 

The total carbon footprint of the ES90 is 31 tonnes when using a European energy mix and 26 tonnes with wind energy. 

Volvo says that with a European energy mix, the ES90’s footprint is 50% lower than the Volvo S90 mild hybrid variant and 30% lower than a plug-in hybrid S90.

As a result, the ES90 is one of the lowest carbon footprints of any Volvo car to date. 

Production is set to start in late Summer of 2025, with the first orders of the EV expected to be delivered to customers in Spring 2026. 

“We go above and beyond existing legislation and have clear ambitions because that is important to us,” says Vanessa Butani, Head of Global Sustainability at Volvo Cars. 

“We aim to achieve net-zero greenhouse gas emissions by 2040, and our ambition to be a leader in electrification is one step in that direction. The ES90 represents our holistic approach to sustainability, including the circular economy, climate-neutral manufacturing and responsible business.” 

The first automotive manufacturer to release LCA reports

Volvo first launched its fully electric cars in 2019, alongside its pledge to release Life Cycle Assessment (LCA) reports for all its global fully electric models.

By publicly issuing the reports, Volvo aims to help customers make informed decisions when choosing their next electric car.

It has since issued LCA reports for five models: EX40, EC40, EX30, EX90 and now the ES90.

Outside of being a full electric car with zero tailpipe emissions, the ES90 has been fully designed with sustainability in mind. 

For example, the use of the new 800-volt electric system with lighter components that reduce the car's overall weight and increase its charging and energy efficiency. The car’s design also delivers a drag coefficient of 0.25, the best in Volvo's history.

The ES90 is also made with 29% recycled aluminium, 18% recycled steel a and 16% recycled polymers, as well as bio-based materials including FSC-certified wood in the cabin.

ES90 also features Volvo’s world-first battery passport, based on blockchain technology that allows the company to track the origin of raw materials and the overall health of the battery.

Not only is Volvo designing sustainability into its vehicles, but the company says it is dedicated to reaching net zero by 2040.

Where the company is manufacturing the ES90 in its Chengdu Plant, Volvo has switched from natural gas to biogas, which has led to a carbon reduction of 50% per vehicle during the manufacturing phase. 

Sustainable procurement and supply chain

Volvo is committed to reducing its climate impact across its value chain. 

By working directly with contracted suppliers, Volvo’s direct materials suppliers are requested to set targets and perform actions towards climate-neutral energy sources in their own operations and upstream supply chains.

Since September 2023, suppliers have been required to declare recycled material content through the International Material Data System (IMDS). 

This allows Volvo to trace material composition more accurately and enforce consistency across its tiered supply base. 

A guideline on carbon footprint reporting has also been introduced, standardising methodology and enabling comparability across suppliers.

Currently, 11 directly contracted suppliers use 100% renewable electricity in the manufacturing steps, resulting in a reduction of 0.1 tonnes CO₂e per vehicle in the material production and refining phase. 

Additionally, Volvo is committed to its use of recycled materials:

• 75% recycled aluminium is used in wheels, with the remaining primary aluminium smelted with renewable energy
• 30 to 40% recycled aluminium is used in the battery tray and extruded aluminium in the vehicle body
• 80% recycled copper is used in electric motor wiring
• 80% recycled magnesium is used in the cross-car beam
• Up to 50% recycled PP and PC+ABS are used in the instrument panel
• 48% natural materials are used in door panels and 98% natural materials are used in instrument panels and trim mouldings
• 100% recycled PA is used in carpet yarn
• 67% bio-based PA11, derived from castor oil, is used in battery cooling pipes.