A new report from Autocraft EV Solutions challenges misconceptions around battery failure and presents the case for repair over the conventional replace and recycle approach.
The EV battery testing, repair and remanufacturing firm’s report, called ‘Closing the EV confidence gap: the role of battery remanufacturing’, draws on in-warranty repair data and academically verified insights from the RECOVAS project.
It found that localised battery faults require targeted solutions with only 1.1 modules needing to be replaced to restore a pack to optimal performance – above 90% of the original state-of-health. In addition it found a 93% CO2 reduction for each battery repaired (based on a 82.4kWh pack) that is repaired rather than replaced. The study also discovered that 92% of modules in a “failed” battery are still suitable for automotive re-use.
It made three recommendations: make battery repair standard industry practice, end premature recycling of healthy battery compontents, and designing EV batteries for repairability.
RECOVAS was a collaboration between automotive businesses to quantify the impact of the battery life cycle, to demonstrate how remanufacturing can play a major role in boosting confidence in EV and preventing millions of tonnes of avoidable carbon emissions.
The data in the report is based on a sample group of 559 commercial repairs carried out in 2024, providing the most up-to-date picture of EV battery repair needs.
Dr Sara Ridley, Engineering & Quality Director of Autocraft Solutions Group, said:
“Despite EV battery failure rates being very low, we need a better plan for when they do occur. The assumption that EV batteries need full replacement when a fault occurs is simply not true, given that most batteries can be repaired.
“The mere possibility of battery failure undermines the perception of EVs, with many people unwilling to entertain the risk. Our goal is to change this narrative, giving buyers confidence that their EV batteries can be efficiently repaired rather than replaced at great expense or worse, prematurely scrapped.”
“A battery can only perform to the level of its weakest performing cell. Autocraft’s OptEVizer dynamic testing protocols provide a comprehensive picture of battery state of health at a cellular level. While battery repair is far from simple, our REVIVE remanufacturing capability means it can be done safely, reliably, and at scale. As EV adoption grows, consumer confidence in battery longevity and repairability will be crucial to sustaining momentum.
“By making battery repair an industry norm, we can help drive a stronger EV market.”
Image courtesy of Autocraft EV Solutions
