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Faraday Future has built at least part of a car

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Faraday Future, the Tesla rival hopeful nearly written off not that long ago amid financial woes and promises of eye-wateringly expensive cars, is nevertheless inching closer to production of its first model, dubbed FF91. The luxury EV startup has recently completed a body-in-white, which is an automotive industry term for a finished unibody structure without interior equipment, trim, wheels or engine, but completed with the same processes that will be used in production. It is typically a major milestone on the road to mass production, which Faraday Future hopes to start later this year, planning to offer the first cars in December.

The company reached this milestone slightly ahead of schedule, overcoming complex manufacturing goals such as welding steel to aluminum and using wireless "transducerized" torque tools to assemble the body. The structure of the FF91 uses more than 1,500 self-piercing rivets in addition to Flowform screw technology, along with more traditional sheetmetal joining methods. And aluminum-to-steel welding, a difficult task even for large automakers, requires Flexweld resistance element welding methods.

"There is no question that this team and our suppliers have faced many significant challenges in getting FF 91 to this point, and even slightly ahead of schedule," said Dag Reckhorn, senior VP of manufacturing. "This is really a huge accomplishment over these past two years. All while focusing on the true luxury and quality of the final product. Our constant focus on teamwork, avoiding functional ‘silos’, has paid off."

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