Design
The production Chevy Volt is more than just a good-looking vehicle. Its design has been carefully crafted to accommodate the T-shaped battery pack and to maximize aerodynamics. A key consideration for GM designers was reducing aerodynamic drag, which accounts for about 20 percent of an average vehicle's consumed energy. The battery pack alone is nearly 6 feet long and weighs more than 375 pounds. Designers located the T-shaped battery down the car's center tunnel and under the seats, integrating the battery with the vehicle's structure. This central placement also provides greater battery protection, GM claims. To reduce the Volt's overall mass, the vehicle was engineered with a relatively small fuel tank for the supplementary on-board engine, while still providing an extended driving range greater than 400 miles between fill-ups.

The Volt's roofline is low, and acts as an aerodynamic enabler, with the production Volt's coefficient of drag 30 percent lower than the original concept, according to the company. By optimizing aerodynamics in overall styling and packaging, designers helped improve Volt's fuel economy for extended-range driving while retaining the flexibility necessary to create the car's unique and innovative exterior and interior design. For example, the T-shaped battery necessitated moving passengers to the sides of the vehicle. Designers stepped up to the plate, and the Volt's interior will accommodate a 6-foot 2-inch person quite comfortably in both front and rear seats. GM also indicates that designers "shrink-wrapped" the interior, especially the door panels, for comfort and space. In fact, GM claims the Volt has no wasted space at all.