Cupra has begun production of the Raval at the Martorell plant, the first model designed, developed and manufactured entirely at the facility, ahead of a market launch this summer. Nearly 160,000 m² of the factory has been adapted to accommodate Line 1’s new production process, which includes more than 1,000 new robots and a retrained workforce.

Key new equipment includes the PXL press, producing four million parts a year, and absolute inline measurement — a European first using four robotic cameras and six sensors to verify and calibrate body dimensions. Titan robots, at 2.5 metres tall with a payload capacity of up to 1,000 kg, assemble the side panels to the chassis.

The laser cabin for roof welding is among the fastest in the Volkswagen Group, while the painting stage introduces the KTL oven, the first electric oven at the facility, operating with zero CO₂ emissions and enabling distinctive finishes including Iridescent Plasma and Manganese Matt. Together, these steps give the Raval its distinctive visual identity before it leaves the line.

The battery, assembled at an adjacent plant, travels 600 metres via a covered bridge before joining the car platform and electric motor in the bodywork. Production starting ahead of the Raval’s summer launch marks a new chapter for Cupra, which has overseen the car’s complete development and manufacturing at a single site for the first time.

Why this matters:

• Martorell’s transformation is a test case for incumbent OEM electrification at scale.The 160,000 m² adaptation, 1,000 new robots, and dedicated battery logistics infrastructure represent a substantial commitment to in-house EV manufacturing rather than outsourcing or platform-sharing with a dedicated EV facility—and how efficiently Line 1 ramps will offer early evidence of whether legacy plants can absorb that kind of retooling without the productivity penalties that have undermined similar conversions elsewhere.