Aggresive Porsche Assembly line 2025: Making of Porsche Taycan inside German Factory🔩

These employees check the final quality of your Porsche Taycan. This video tells the story of the birth of the latest electric Taycan. The first step in the production of a new car is welding, which means putting together the main frame of the vehicle. 99% of all welding is done by robots only. This video footage is from the Porsche factory near Suffenhausen, Germany. This is where all Taycan cars are built. This is how the panoramic roof is attached. After testing, it is taken off again and attached again on the assembly line. The finished door is quickly and easily attached by a factory worker. Before painting the bodywork, the entire car is checked and, if necessary, wiped down. And now we'll move on to painting the bodywork. Electrophoretic coating is an electrochemical process chiefly used for corrosion protection. During the coating process, the body is dipped for five minutes into a basin. The underbody protection is also applied here. It consists of a material which contains PVC and chiefly protects the body from rock chip. The result of the electrophoretic coating process is an especially smooth and uniform coat of paint on the metal surfaces and in the cavities. Having re-emerged from the basin, the body is dried at 175 degrees for 50 minutes. The last step here is a 40-minute drying process, during which the final cross-linking of the coats takes place at higher temperatures. The polishing device cleans the bodywork of all dirt again. Now painting robots apply the filler on the inside and outside of the body. This coat of paint levels out any remaining unevennesses and possesses UV protection characteristics. Before the bodies receive their final color, they are thoroughly cleaned and any dirt from preceding processes is removed. Only then is the coloring base coat applied using high-speed rotating atomizers. And a fine spray of tiny color particles is given its desired hue. Now it's back to quality control. After the drying process, the vehicle is taken back to ground level and subjected to a thorough visual inspection in the light tunnel. Watch how Porsche employees concentrate and check for every unevenness or irregularity. This tunnel is fitted with strips of LED tubes, which project their light onto the car bodies. The LED tubes create a uniform strip light pattern, which allows quality inspectors to detect even the slightest imperfection in the paint. If there is the slightest flaw in the paint, the body is taken out of the line and transferred to spot repair. At this point, the raw vehicle body has been transformed into a high-gloss Porsche Taycan, which is now taken to the assembly line. But this is component manufacturing. This is where the large parts of the car are assembled and delivered to the main assembly line. In this area, gear transmissions and components such as air conditioning compressors, generators, starters, and servo pumps are attached to the engines delivered. The engines are then subjected to meticulous quality control. If they pass, they are taken to the engagement. Engagement here means that the completed engine transmission unit is placed onto the front axle of the vehicle. Porsche is trying to strike a balance between electrical efficiency and performance. They have used unique manufacturing processes and components. The battery case is fully integrated into the car's structure. Two electric machines, one on each axle, drive the front and rear wheels. The Taycan is therefore all-wheel drive. This is where the robotic arms do much of the work. The orange robots come from the manufacturer KUKA Robots. It is this company that specializes in electrical helpers in most car factories. You can also visit this factory in person. Take a look behind the scenes where the heart and soul of the brand are at home, at the headquarters in Zuffenhausen in Germany. Groups of up to 15 people are guided throughout this factory for approximately 90 minutes. The entrance fee is around 10 euros per person. Much of this detailing is done by workers, so Porsche Taycan cars are largely handmade. This process is also chosen by many luxury manufacturers such as Rolls-Royce and Bentley. After the part is plugged in and sealed with a hatch, it is loaded onto a mobile trolley that distributes the parts around the factory. The location and condition is determined by reading the label. The robotic trolley now knows where to take the part. A special feature of the Taycan electric motors is the hairpin winding. In this process, the solenoid coils of the static consist of rectangular wires instead of round ones. The manufacturing process of hairpin technology is complex, but simply put it allows the wires to be packed more densely. This means that in the same amount of space of a conventional stator, Porsche engineers were able to squeeze out more power and torque. Other components are assembled here including the gears and axles. Together, these make the drive units of the Taycan. The components are sent to final assembly, where they will finally be put together. As you can see, the panoramic roof is now finally attached. Only now, after the painting of the entire bodywork is complete, will the panoramic sunroof be attached by robotic hands using a special adhesive. The control units and roof lining, including handrails and sun visors, are also being completed. The final step on the interior line is the training of the key, which is inserted into the ignition for the first time here. The entire production process is very similar for almost all carmakers. The chassis is assembled separately, and the upper body is assembled also separately. Now you are looking at the front and rear axle connections for the wheels along with the main battery, which is on the bottom of the whole car. The wiring is usually taken care of by human workers, however the handling of these heavy parts is handled by robots and cranes. Now the chassis is ready with brakes, drive and the main battery is connected to the chassis. It can therefore be moved automatically by means of a section of connection to the upper part of the car body. Following work on the exhaust system, axles and steering, the vehicle is ready for marriage, one of the most spectacular steps on any vehicle assembly line. Here, an automated guided vehicle system places the completed drivetrain underneath the associated vehicle body and bolts it firmly into place. In this way, the engine, chassis and body are virtually married. In a final step, the tailpipes are installed. Now let's take a look at the final assembly line. Fitting the Porsche Taycan rear and front bumpers is done in minutes. Employees must wear clothing with the Porsche logo. That's a big difference from car companies in the US. This color is the base color for the new Porsche Taycan and is called Ice Gray Metallic. Prior to installing the wheels, the steering wheel and driver airbag are installed. Subsequently, the wheels are mounted using a handling unit and a bolter. Each wheel weighs 35 kilos and is fastened with 5 bolts. Correct tightening is taken care of by tightening devices and no human error can be made. Now comes the output quality control. Under LED lighting, inspectors check the final quality of the Porsche Taycan. Your future car will undergo a complete inspection here. At their end, there are no defects. In the test bay, the vehicle is placed on its wheels for the first time. After the programming of various control devices comes another exciting moment. The engine is started for the first time. Further steps include some final chassis and headlight tuning and the calibration of the driver assistance systems. The wheel alignment is measured with tracking cameras and adjusted manually. A steering wheel balance guarantees the straight-ahead position of the steering wheel. On completion of these steps, the vehicles are then taken to the chassis dynamometer for a driving simulation at a maximum speed. After starting up at this Porsche factory, some Taycan test cars take to the road to test their driving abilities. Both the interior and exterior are in keeping with the highest class of cars. Let me know in the comment section how you like this car and if you would like to own a Porsche Taycan.