Cost-Effective Battery Repair for Aging Electric Vehicles

In a notable case from Berlin, the owner of a twelve-year-old Smart Electric Drive recently discovered that a costly battery replacement was not the only option available when his vehicle's range began to diminish. Instead of opting for the standard practice of replacing the entire battery--which would have incurred expenses in the thousands of euros--the owner explored the possibility of repairing only the defective cells within the battery.

As electric vehicle (EV) batteries age, it is typical for them to lose some of their capacity after extensive use, such as driving over 300,000 kilometers. The vehicle's original eight-year warranty had expired, making the prospect of a full battery replacement economically unfeasible. The battery is known to be the most expensive component of an electric car, and replacing it outright can often amount to a total loss for older vehicles.

Experts note that when an EV's battery performance declines, it is rarely due to the failure of the entire battery block; instead, it is often individual cells that weaken over time. This can create a cascading effect where the overall battery performance is compromised. One analogy used to illustrate this issue compares battery cells to glasses of water that are supposed to be filled evenly. Over time, however, some glasses may leak more than others, leading to significant capacity loss even if most cells remain functional.

After assessing the situation, the vehicle owner sought assistance from EV Clinic in Berlin, where technicians were able to repair the faulty cells at a fraction of the cost of a full replacement. The service provided a remarkable benefit, enhancing the vehicle's range by 20 percent, and the owner was pleasantly surprised to find the total repair cost amounted to just 900 euros.

This case exemplifies a growing trend in the electric vehicle sector: prioritizing battery repairs over full replacements. Research conducted by the Chair of Production Engineering of E-Mobility Components at RWTH Aachen University, in collaboration with industry partner Henkel, highlights the environmental and economic advantages of repairing battery modules rather than replacing entire battery packs. According to the study, repairing could reduce costs by up to 77 percent and emissions by up to 91 percent compared to full replacements.

Such practices not only present advantages for vehicle manufacturers, particularly during warranty periods but also prove beneficial for consumers, even once warranties have lapsed. Furthermore, the push for battery repair aligns with broader sustainability goals, contributing to a circular economy for battery systems and making electric vehicles more environmentally friendly.

As the automotive industry continues to evolve, the focus on sustainable practices in battery management represents a significant shift, potentially transforming how electric vehicles are maintained and enhancing their longevity.