Maybe not a full-scale brand like Toyota or Honda but a “boutique” sports car manufacturer such as Pagani, TVR, Rimac, etc. Some processes can probably be performed by hand (assembly, welding, painting, etc.) and not need expensive ABB, Fanuc, Dürr, Samsung, Kuka, etc. robots. Also: things like engine, transmission, differential, brakes, steering/suspension, airbags, sensors, lights/reflectors such as Hella 4169 etc. can probably be purchased instead of manufacturing yourself.
Expenses I can think of:
- Establishing the actual corporation, LLC, etc
- Buying/renting a large warehouse
- Sheet metal stamp/press for body parts
- Metal forge for suspension components
- Mold for polypropylene bumpers
- Mold for ABS parts (mirror caps, handles, etc)
- Machine to create all the glass
- Fiberglass station
- Welding equipment
- Paint line, paint booth and oven/curing
- Interior/upholstery department
- Storage aka parts department
- Lifts/dollies/conveyor belts for assembly line
- Crash testing 7 or more cars to legalize them
- Getting the cars federalized/legalized/homologated
- Getting the factory certified, similar as above
- Payroll for managers, marketing, laborers, janitors, maintenance, etc.
- Insurance and lawyers
- Upfront capital for purchasing raw materials
Obviously the starting price would be several million dollars even in a country like Vietnam, India or Mexico - but does anybody have a more specific answer? Can it be done for under $10m? Under $50m? Under $100m? Under $250m?
It would probably be low volume production due the cost effective nature, but the number still interests me.
You can check financial statements for these recent EV startups to get an idea but Lucid lost $631M in Q3 this year. Their cars cost $470M to make, R&D cost $231M, and business costs were another $190M. They only had $138M in revenue. I think Lucid’s costs are wildly out of scale and probably something fishy is happening behind the scenes but that’s a data point