Flame Nova used to be a normal sized bot once upon a time. Same size class as the likes of Blue Cop and Phoenix Fire. He was always made to be a Star Guardian, and was destined to be a leader, but he had to prove himself.
Once he did, Deus Machina would call him to her chambers and present him with the three other vehicles that would make up his current body, along with an upgraded card, which turned his flame thrower cannon into the Flame Armor, and turned the cannon into a the cannon that appears on his left arm as we know it now.
Flame Nova accepted the permanent upgrade, which changed his frame completely. It was an addition deep in his core that allowed more power to flow through him without it becoming dangerous. A Combination Receptor. Without this small device implanted onto the core, a bot can still combine with other, non-sentient vehicles that become attuned to them, but the bond cannot be permanent. It can exhaust or even kill those who try to make it last longer.
Once Flame Nova was able to receive this Combination Receptor, he was then able to permanently combine with the other vehicles, attuning them to his consciousness past the point of a regular combination. He could see and remember things from the other vehicles when he split apart. But he could never return to the form he used to hold. The Combination Receptor changes the frame so much that they cannot go back once they have settled into this power.
Meanwhile, Blue Cop eventually became strong enough to combine, but without Deus to bestow him with a Combination Receptor, his combinations could never be permanent. That's why he couldn't see or remember things from his Trinity vehicles, and why he couldn't hold that form and would always return to his normal form. But also, it's why he *could* eventually combine with Blaion.
He had been on the path to getting a Receptor, but unfortunately, the death of the planet did take all of them with it. Though, Deus did hide his power card data in the Metal Breaths so that he could at least access that power.
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