State of Development


An overview of all important phases of vehicle development.

Development Partners

We're developing the Sion together with over 50 well-known suppliers and engineering service providers. Here you can find a selection of them.

Development News


The design of the Sono Wallbox: A first result is available

14th September 2021 – On 2 September it was finally time for us to present to you the Sono wallbox. Now we are excited to show you the first Results of the Sono Wallbox.

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Blog Post

We’re Developing a Bidirectional Wallbox - How It Looks Is up to You

2nd September 2021 – The Sono wallbox makes it possible to use the Sion as a home storage system since it enables the Sion to deliver electricity to a building. But which applications will be possible? How expensive will it be? And what will it look like? Product manager Tillmann Laux has the answers.

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Blog Post

Digital Mobility: All you need to know about our partnership with Sibros

19th July 2021 – We have found a strong partner in the Californian software company Sibros. My colleague from Sono Digital Johannes Bückle and I had the opportunity to talk to Hemant Sikaria, CEO and co-founder of the company, about our partnership, goals and the next development steps.

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Development Steps

Faster Into Production With Only One Variant

We do many things differently. For example, we produce the Sion in only one variant and color. This means less development time and shortens procurement, testing and vehicle build. The majority of our components come into the Sion as so-called "carry-over parts" and therefore only have to be tested in the vehicle environment. We also shorten the test duration by focusing on simulations early in the development phase. We have close and good relationships with our partners. We develop new and efficient processes with them right from the start. This saves us valuable time.

Status Quo

We sent even sent our first vehicles (SVC1) on test drives early on in the concept phase. This enables us to get us direct feedback from those who were interested in the idea of the Sion. We quickly found enthusiastic supporters who joined together to form a Community and whose opinions and feedback were integrated into further development phases. At the same time, we built Sono Motors, hired a team of one hundred people and developed organizational structures. Of course, a wide network of partners and suppliers was also set up. Successful completion of the concept phase means we are now in the final third of the design phase. Through design loops and simulation, all homologation requirements are already tested on the virtual vehicle.

The Next Milestones

In the final stage of the design phase it is important, among other things, to reach the next stage of vehicle maturity (SVC2). These vehicles are mainly used to calibrate the powertrain and to tune the chassis. At the end of this phase, the next milestone is reached: the development release for the series prototypes (design release PB). Here, the toolings, mainly "soft toolings", are ordered to reach the next level of maturity (SVC3).

The Testing Process

The completion of the procurement phase, which involves tool manufacturing, part production and testing, logistics and pre-assembly, is followed by the MRD (material required date). With that the assembly of the bodies (BIW) and prototypes begins in the prototype shop. Once the first hardware has been completed, the test phase begins. Here, the functional tests and crash tests are carried out to ensure that the requirements from the specification and homologation are met. In the subsequent design update phase necessary changes are incorporated into the virtual vehicle. At the end there is then the milestone design release MB, with the completion of which we then start the procurement of series toolings.

The Production

Here, the production trial begins, the assembly of the first vehicles at our contract manufacturer on the production line (Body Shop and General Assembly). The PPAP process (Production Parts Approval Process) is simultaneously initiated at our suppliers. Now the final tests for the type approval are carried out with vehicles from production. When successful type approval is received and the the PPAP completed, series production of the Sion (SOP) begins.

The Delivery

We want to get the Sion onto the road as soon as possible. Good project management of course always includes a realistic risk assessment. This is especially relevant in a company like ours, as transparency and openness are important to us. Our experienced development team continuously evaluates possible risks. In our overview, potential delays due to possible risks are presented transparently. We continuously evaluate all events and development steps in order to be able to react quickly and to avoid delays.