Toyota Mirai production line: FC Stack installation

Toyota Mirai production line: FC Stack installation

Toyota just released a set of photos and videos from the Mirai production line in Toyota City, Japan.

Pace of work is measured at just three cars per day, so we'll round it to 1,000 Mirai built per year.

The whole process seems very cautious, meticulous and focused on quality, which we're certain leads, at least in part, to the high price of the car ($57,500 before up to $13,000 incentives).

"Toyota ushered in a new era in vehicle technology last November with the launch of production of its Mirai hydrogen fuel cell-powered saloon. The factory chosen for the task is the Motomachi plant in Toyota City, home to many landmark models, most recently the Lexus LFA supercar.

The small but dedicated facility is charged with producing Mirai with the same care and attention to detail that was paid to the LFA. Production of the Lexus V10 coupe was limited to just 500 examples, with the last model coming off the line just over two years ago; Mirai is being manufactured at a rate of around three cars a day.

A new series of short films goes behind the scenes at Motomachi to reveal key stages in the production process, right through to the final inspection every car undergoes before leaving the plant.

Production started at Motomachi in 1959 and in its 56-year history it has produced such renowned Toyotas as Publica, Corona, Cresta, Soarer, Supra and RAV4. Mirai is now on sale in Japan and will be introduced in limited numbers to the UK and other selected European markets during 2015."

If you've ever wondered how hydrogen fuel cell cars are produced, these images and videos from the Japanese automaker will not disappoint:

Toyota Mirai production line: FC Stack installation

Toyota Mirai production line: FC Stack installation

Toyota Mirai production line: FC Stack installation

Toyota Mirai production line: FC Stack installation

Toyota Mirai production line: FC Stack installation

Toyota Mirai production line: FC Stack installation

Toyota Mirai production line: quality gate

Toyota Mirai production line: quality gate

Toyota Mirai production line: quality gate

Toyota Mirai production line: quality gate

Toyota Mirai production line: quality gate

Toyota Mirai production line: quality gate

Toyota Mirai production line: quality gate

Toyota Mirai production line: quality gate

Toyota Mirai production line: quality control and inspection

Toyota Mirai production line: quality control and inspection

Toyota Mirai production line: quality control and inspection

Toyota Mirai production line: quality control and inspection

Toyota Mirai production line: quality control and inspection

Toyota Mirai production line: quality control and inspection

Toyota Mirai production line: quality control and inspection (hydrogen leak testing)

Toyota Mirai production line: quality control and inspection (hydrogen leak testing)

"Before each Toyota Mirai body is brought to the former LFA Works assembly line, it is painted at the mass production line at Motomachi Plant. The vehicle doors are then removed to enable more efficient interior work for Toyota’s highly skilled craftspeople, as well as preventing doors from being damaged. This video also showcases: wire harness, dash silencer, brake fluid tank, rear combination lamp, instrument panel, main battery, roof lining, and rear bumper installation."

"The Toyota Mirai fuel cell sedan features a CFRP Stack Frame which is produced at the assembly area of Toyota’s Motomachi Plant, formerly the LFA Works. Following the installation of the fuel cell stack, the boost converter, hydrogen tank and tubes are fitted to the vehicle. This video also shows the hydrogen leak test which is performed using helium. Next, the vehicle’s fuel cell stack and hydrogen tank are installed at the same time, followed by preparation of the electric motor and marriage of the air compressor to the fuel cell stack. Before the chassis assembly is complete, the drive shaft, front axle, inverter, water heating unit, high voltage cable, front suspension, motor, rear axle, front bumper and wheels are installed.

Note: CFRP = carbon fiber-reinforced plastic"

"The final processes before the Toyota Mirai fuel cell sedan rolls off the assembly line are the installation and assembly of the external power supply system, vehicle interior, engine bay, windshield, and rear windows. The glue used to affix the windows to the frame is 8 mm high and 12 mm wide, applied by highly skilled craftspeople at a consistent rate. This video also features the final interior trim installations, including: seats, doors, steering wheel and inverter cover. An ignition check is then performed on the vehicle before it is send for final inspection."

"Detailed quality control and inspection is performed on the Toyota Mirai before it leaves the Motomachi Plant, on its way to customers. Toyota specialists use both visual and tactile inspection to ensure the vehicle is of the highest quality and without any defect before leaving the factory."

"The assembly line for the Toyota Mirai is divided into three main sections: trim, chassis/fuel cell assembly, and final assembly. In each section, there are sub-assembly areas for parts installation. This video shows an overview of the production line as well as the parts selection process located close to the assembly line."