On Thursday, Kia unveiled its next-generation production method—the Flexible Body System—applied to its first purpose-built vehicle (PBV), the PV5.
This system modularizes major components—chassis, movable parts (doors, tailgate), exterior, interior—enabling flexible development and production of various configurations. Kia says that by applying the system to the PV5, it secures design flexibility, production efficiency, structural stability, and ease of maintenance for multi-model lines.
All PV5 variants share the same front section and first-row cabin layout. Beyond the first row, modules such as rear overhang, tailgate, quarter glass, and roof can be selectively combined. This modularization allows for up to 16 different body variants, with seven initial configurations: Passenger-Long, Cargo-Compact (3-door and 4-door), Cargo-Long (3-door and 4-door), and Cargo-High-Roof (3-door and 4-door).
For example, the Cargo Long variant is created by sliding the rear overhang module backward and inserting a long‑body module between the D‑pillars. Replacing the quarter‑glass and tailgate modules converts it to a Passenger variant.
Kia also adopts assembly-type rear-side garnishes and an external skeletal ring structure to ensure both flexibility and safety, while improving maintainability.
The rear side garnish, located beyond the D-pillar on the vehicle’s exterior, is made of a plastic composite that is easier to mold than traditional steel panels. Its design allows for variations in size and shape depending on the vehicle’s length, height, and intended purpose. Composed of three sections, the garnish enables easy replacement of only the damaged part in the event of a rear collision or scratch, thereby improving maintenance convenience and reducing repair costs.
Building on this structure, Kia has applied an expanded external skeletal ring to the vehicle’s frame, which enhances structural stability while minimizing noise, vibration, and harshness (NVH). In long-body models, this skeletal ring is applied in a dual configuration, extending across both the rear overhang and side modules, to reinforce the body’s rigidity further.
This month, Kia begins mass production of the PV5 Passenger 5-seater and Cargo Long models, with additional variants to follow. By 2027, the company plans to introduce a full‑size PBV, expanding its portfolio and support diverse market needs.
Youngho Lee, Executive Director of Kia’s MSV Body Design Division 1, commented that while adopting a Lego‑style modular assembly was initially a challenge, it ultimately represents a pivotal shift in vehicle development for the PBV era. He affirmed Kia’s commitment to ongoing innovation for customizable vehicles that adapt quickly to changing customer needs.