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Study Shows That 92% Of Modules Remain Functional After Failure And That Repair Can Reduce CO₂ Emissions By Up To 93%, Making Maintenance More Efficient And Sustainable.
A recent study by Autocraft EV Solutions revealed a surprising fact: most failures in electric vehicle batteries can be repaired by simply replacing 1.1 defective modules, restoring over 90% of the original capacity.
The finding debunks one of the main myths surrounding electric vehicle batteries — the idea that when the battery fails, it must be replaced entirely.
Defective Modules, Not The Whole Battery
The analysis was based on 559 commercial repairs and indicated that, in most cases, the problem lies in individual cells, not in the battery as a whole.
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With the use of tools, it is possible to accurately identify the point of failure.
This technical advancement enables targeted and more efficient actions, with lower cost and environmental impact.
CO₂ Savings And Reuse Of Modules
Repairing a battery instead of replacing it generates a significant savings in terms of emissions.
Autocraft pointed out that the reduction can reach 93% in CO₂ emissions. For an 82.5 kWh battery, this represents a savings of up to 12 tons of carbon per unit.
Another important fact is that 92% of battery modules considered faulty still function and can be reused in other systems.
This practice extends the life cycle of components and reduces the need for the extraction of materials such as lithium, cobalt, and nickel.
Sector Needs To Change Urgently
The study identified three priority changes to make repair a reality on a large scale. The first is standardization of repair, which should become common both inside and outside vehicle warranties.
The second is the end of premature recycling. Recycling still plays an important role, but it should be a final step, not the first response.
The third and most challenging change is the redesign of batteries. Currently, many models make repairs difficult, leading to complete replacement even when only one module is damaged.
The recommendation is clear: it is necessary to adopt modular designs that facilitate access to internal components and allow for simple repairs.
Faster And Sustainable Energy Transition
The approach proposed by Autocraft points to a new model of sustainability. With more durable and repairable batteries, there will be less need for mining, less waste generation, and greater savings of natural resources such as water and energy.
Additionally, this change can reduce the final cost of electric vehicles, making them more accessible to the public.
It also increases consumer confidence, who often worry about future maintenance and battery replacement costs.
The study concludes that repairing electric vehicle batteries is not just a viable alternative — it is an essential strategy.
This practice has the potential to accelerate the energy transition, preserve natural resources, and significantly reduce the carbon footprint.
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