From hybrids to horsepower Nissan’s cold-spray breakthrough changes combustion forever

Nissan eco hybrids are moving into production with an engine that uses cold-spray technology, a method that changes how cylinder heads are built.

Instead of inserting separate valve seats, the process sprays metal directly onto the cylinder head surface.

This creates a simpler, stronger structure with better heat control during combustion.

The first cars using the system are already in the pipeline, and Nissan plans to expand it across more hybrid drivetrain models worldwide.

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Cold-spray tech changes eco hybrids

Engines have always relied on valve seats to manage combustion pressure and heat.

These inserts are pressed into the cylinder head, but they restrict airflow design and require additional parts.

Nissan’s cold-spray technology replaces that step by firing metal powder at high speed onto the aluminum head, bonding it firmly without melting the material.

The result is fewer components inside the engine and better cooling around the valves.

The new 1.5-liter turbocharged unit that uses this method sits at the center of the company’s e-Power hybrid drivetrain in Europe.

Nissan says the design reaches 42 percent thermal efficiency, a figure rarely achieved by gasoline engines.

Without valve seat inserts, engineers can shape intake and exhaust ports more precisely.

The airflow improvements bring gains in both performance and fuel use.

Nissan has paired the cold-spray process with its STARC combustion system, designed to keep combustion more stable and efficient.

What’s next for Nissan

The first production model with this engine is the Qashqai, built in Sunderland, UK.

The Elgrand minivan in Japan is scheduled to adopt the same cold-spray technology in 2026.

The next-generation Rogue is expected to bring the hybrid drivetrain to North America, expanding the rollout further.

Reducing the number of parts also simplifies production and lowers the risk of failure over time.

That helps durability and keeps assembly lines more efficient.

For Nissan, the approach gives its eco hybrids a way to compete strongly in markets where hybrids remain in high demand.

Eco hybrids built with this Nissan engine show how targeted manufacturing changes can reshape drivetrain development.

Cold-spray technology removes a key limitation in combustion design and creates more options for efficiency in future hybrid models.

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