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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 of Autocraft EV Solutions revealed a surprising fact: most failures in electric vehicle batteries can be repaired by simply replacing 1,1 defective modules, restoring more than 90% of the original capacity.
The discovery debunks one of the main myths surrounding electric vehicle batteries — the idea that when a battery fails, it needs to be replaced entirely.
Defective modules, not the entire battery
The analysis was based on 559 commercial repairs and indicated that in most cases the problem lies with individual cells, not 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 advance allows for localized and more efficient actions, with lower costs and environmental impact.
CO₂ savings and module reuse
Repairing a battery, rather than replacing it, creates a saving significant in terms of emissions.
Autocraft has found that CO₂ emissions could be reduced by up to 93%. For an 82,5 kWh battery, this represents a saving of up to 12 tonnes of carbon per unit.
Another important fact is that 92% of the battery modules considered to have failed still work and can be reused in other systems.
This practice extends the life cycle of components and reduces the need to extract 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 the standardization of repair, which should become commonplace both inside and outside vehicle warranty.
The second is an end to premature recycling. Recycling still has an important role, but it should be a final step, not the first response.
The third and most challenging change is the redesign of the batteries. Currently, many models are difficult to repair, leading to complete replacement even when only one module is damaged.
The recommendation is clear: it is necessary to adopt modular designs, which facilitate access to internal components and allow for simple repairs.
Faster and more 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 in natural resources such as water and energy.
Furthermore, this change could reduce the final cost of electric vehicles, making them more accessible to the public.
It also boosts consumer confidence, as consumers often worry about future costs for battery maintenance and replacement.
The study concludes that repairing electric vehicle batteries is not just a viable alternative — it is an essential strategy.
The practice has the potential to accelerate the energy transition, preserve natural resources and significantly reduce the carbon footprint.
