Study Found That Defective Electric Vehicle Batteries Can Recover Up to 90% Of Their Lifespan With Simple Repairs

Written by Fabio Lucas Carvalho

Published on 10/05/2025 at 07:13

Updated on 10/05/2025 at 07:15

Foto: Reprodução

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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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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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Study Found That Defective Electric Vehicle Batteries Can Recover Up to 90% Of Their Lifespan With Simple Repairs

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.

Defective Modules, Not The Whole Battery

CO₂ Savings And Reuse Of Modules

Sector Needs To Change Urgently

Faster And Sustainable Energy Transition

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Study Found That Defective Electric Vehicle Batteries Can Recover Up to 90% Of Their Lifespan With Simple Repairs

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.

Defective Modules, Not The Whole Battery

CO₂ Savings And Reuse Of Modules

Sector Needs To Change Urgently

Faster And Sustainable Energy Transition

A giant printer called the “Ferrari” of concrete has landed in Latin America and can already build a 120-square-meter house in just 48 hours, making the traditional construction site look like something from the last century.

Brazil will harvest a record crop of up to 357 million tons of grains, but it does not have the capacity to store a large part of it. The storage deficit has reached the highest level in history and is equivalent to almost the entire production of Argentina.

Four times faster than the Concorde, capable of taking passengers from New York to London in less than an hour at Mach 5.5, and with an engine that switches from turbojet to ramjet mid-flight at Mach 3.5, the Hermeus Quarterhorse went from paper to its first flight in just 19 months.

She started by collecting oyster shells from restaurants and today she has already accumulated more than 10 tons to restore reefs, recover coastal habitats, and demonstrate how a common waste can become a tool for ocean conservation.

SpaceX will dock a $843 million vehicle to the International Space Station to push a nearly 420-ton laboratory against the atmosphere and make the debris fall in a controlled manner into the ocean.

China opens the world’s first school where more than 100 humanoid robots from different brands will study together, each movement will be repeated up to 600 times a day and the data will feed a collective brain that will teach all the robots of the future.

Three teenagers surprise the world by creating a powder with tamarind seeds that removes microplastics from water, requires no electricity, and wins an international prize of $12,500 at The Earth Prize 2026.

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