A new report from Autocraft EV Solutions, a company specializing in electric vehicle (EV) battery testing and remanufacturing, argues that repairing EV batteries instead of replacing them could significantly reduce carbon emissions and increase consumer confidence in EV ownership. The report, Closing the EV Confidence Gap: The Role of Battery Remanufacturing, is based on in-warranty repair data and insights from the RECOVAS research initiative.
Autocraft’s analysis highlights that most EV battery issues stem from isolated cell failures rather than total system failure. On average, just over one module per battery pack required replacement to restore performance to over 90% of its original capacity. This repair-first approach, according to the report, results in a 93% reduction in CO₂ emissions compared to the environmental cost of replacing and recycling an entire 82.5 kWh battery pack.
“Despite EV battery failure rates being very low, we need a better plan for when they do occur,” said Dr. Sara Ridley, Engineering & Quality Director at Autocraft. “The assumption that EV batteries need full replacement when a fault occurs is simply not true.” Ridley noted that effective battery repair could help reduce hesitation around EV adoption by offering a more cost-effective and sustainable solution.
The report outlines three recommendations for the industry: make repair the standard response for in-warranty battery failures, prioritize the reuse of functional cells to avoid premature recycling, and design future batteries with repairability in mind. Autocraft’s in-house technologies, including its OptEVizer® diagnostics and REVIVE® remanufacturing platform, are designed to facilitate safe and scalable repairs.
Based on 559 commercial battery repairs conducted in 2024, the findings suggest that 92% of modules in a “failed” pack are still viable for reuse. The report underscores that remanufacturing practices could extend battery life, reduce waste, and help the EV industry meet environmental and economic goals.