FOREWORD
TOM KELLY EXECUTIVE DIRECTOR & CEO AUTOMATION ALLEY
Will internal combustion engines (ICE) have a horse and buggy moment? Can existing infrastructure support a large-scale adoption of EVs? Where does hydrogen fit into the equation? What will be the quintessential American car of the future?
If we had these answers, there would be no need for a discussion about the future of mobility and electrification — but this is a discussion worth having. The industry and nation at large is faced with a generational challenge of how mobility will be defined for the masses.
The change thus far for carmakers has been difficult. The average sale of an EV netted a $6,000 loss for a carmaker in 2024. Ratcheting up the pressure is 47% of car buyers are looking for EVs below the price of $40,000 while the average transaction price of an electric car is $61,000.
In the midst of these growing pains and challenges, however, the long game leans toward EVs. A Life Cycle Assessment of EVs showed they emit 37% less CO2 than ICE vehicles, with 100% of the aluminum and 98% of the lithium capable of being
DON HUTCHISON
DEAN OF ENGINEERING & ADVANCED TECHNOLOGY
MACOMB COMMUNITY COLLEGE
recycled from their batteries. Furthermore, EVs are 2.6 to 4.8 times more efficient at traveling a mile compared to a gasoline internal combustion engine and have half of the yearly fueling cost when comparing the cost of gas to that of electricity. Lastly, even when accounting for manufacturing, the EPA found greenhouse gas emissions from EVs are typically lower over its lifetime than gasolinepowered vehicles.
Join us as we take on these mobility trends with experts and stakeholders from academia, government, and industry.
Our experts will bring to light innovations that are being made, address the need for robust charging infrastructure as well as answer what role does clean and sustainable energy play in the future of mobility, and how can sustainable energy and EVs work better together.
We live in an exciting time in mobility and EVs. Let us support each other as industry partners through the electrification and mobility transition.
A SPECIAL THANKS TO THOSE WHO CONTRIBUTED TO THIS REPORT
TOM KELLY EXECUTIVE DIRECTOR & CEO AUTOMATION ALLEY
DR. CHEN DUAN ASSISTANT PROFESSOR KETTERING UNIVERSITY
DAN STEWART RELATIONSHIP MANAGER AUTOMATION ALLEY
DON HUTCHISON DEAN OF ENGINEERING & ADVANCED TECHNOLOGY MACOMB COMMUNITY COLLEGE
CHRIS OLZEM MOBILITY INNVATIONS COORDINATOR OAKLAND COUNTY JACK JOHNS ECONOMIC DEVELOPMENT PROGRAM DIRECTOR MACOMB COUNTY
ENGINEERING dSPACE
DR. V. (ANTHONY) ANANTHANARAYANAN PRESIDENT AND CHIEF TECHNICAL OFFICER INNOVATIVE WELD SOLUTIONS
ROBERT JOHNSON SENIOR VICE PRESIDENT AEROSTAR MANUFACTURING
DWAYNE MCKENZIE DIRECTOR OF KEY ACCOUNTS NEW EAGLE
MITCH ZAJAC SHAREHOLDER BUTZEL
GVSC
SUK-KYU KOH PRESIDENT CHRYSAN
MIKE MILLER VICE PRESIDENT, SALES ORION MEASUREMENT SYSTEMS
DR. ALLAN TAYLOR ASSISTANT PROFESSOR OF ELECTRICAL ENGINEERING KETTERING UNIVERSITY
HAROLD PANGILINAN TECHNICAL EXPERT, VEHICLE ELECTRIFICATION U.S. ARMY DEVCOM GVSC
MARK STANCZAK PRESIDENT GLOBAL ET
JOHN FALCON SVP / CHIEF OPERATING OFFICER ROSS CONTROLS
Electrification Across Industries: Shaping the Future of Mobility with Batteries, Connectivity, and Infrastructure EXPERT INSIGHTS:
By Mitch Zajac, Shareholder
Whether your company is a member of the automotive supply chain, the public transportation industry, or a developer in the personal transportation industry, the future of mobility in your industry includes some aspect of electrification. Battery development, connectivity, and charging stations are among the key elements of electrification facing each and every industry adopting electrified powertrains and advancing alternative energy solutions.
There are many electrification trends shaping the future of mobility. These trends extend far beyond the automotive industry and include rail, aviation, off-road transport, and personal transportation. Each of these industries face various technical challenges, like the development of battery technology for improved charge timing, battery charge capacity, and battery range extension. Electrification in these industries also faces competitive challenges like exploration of hybridization and fuel-cell technologies. And beyond that are the challenges of cooperation with utility companies and
policymakers to improve opportunity for electrified transportation development (primarily infrastructure) but also to ensure continuity of policy across the country so that private and public investment can be well-reasoned and relied on despite the charged political climate (pun intended).
The challenges with infrastructure are likely the biggest, and that is not just roll-out of more charging stations. Rather, the concern facing many in these various industries, and that should include homeowners alike, is the reliability of the power grid itself–not only nationor region-wide, but also in local communities, down to the subdivision level as well. Concerns of electricgrid overload, the availability of remote distribution of electricity, and the development of energy sources sufficient to power the increased demand with electrification are all relevant issues that need to be addressed. Continued on
Like the rollout of sustainable and renewable energy systems over the last few decades, industry players continue to develop solutions to these challenges. For instance, technology advancements certainly have focused on new battery technology solutions, from dual chemistry and solid-state technology development for in-vehicle use, to portable DC fast-charging stations to address the shortage of rural, farming, and remote availability of charging stations. Utilization of these renewable and non-oil-based energy sources (like wind, solar, hydro, and nuclear) are also thought by many to be a "must" in order to support expanded adoption of electrification.
Industry leaders are also focused on expanding partnerships with policymakers and utility companies to address roadblocks in infrastructure development. Today, implementation of key infrastructure requirements can take months to be approved in some municipalities, and upwards of 30-to-36 months to receive materials, be scheduled, and have installation completed. Laws in different states also often prevent the rollout of charging stations under existing utility protections. Some states, including Michigan, are working collaboratively to rollout solutions to encourage electrified transportation solutions. These collaborative initiatives are proving successful in promoting sustainable mobility practices, but continued attention is required in order to overcome the hurdles to fully integrate electrification as a mainstream solution across all industries. Much of the talk in the industry also includes discussion on the topic of integration and operation of software within these various electrified mobility and energy transfer solutions. That discussion also must include the importance of protections against the risk of hacking and mobility
To accomplish widespread adoption, collaboration is needed from all stakeholders. Industry leaders are aware of this, and they are certainly leading the "charge."
cybersecurity. Big risks exist as these industries become more and more electrified and rely more heavily on software integration and connectivity. All electronic systems use vast amounts of data, and that data is at risk for hacking, spoofing and deletion, and users of the data must take steps to ensure data integrity. Controlled Area Network (CAN) bus attacks are the most reported-on type of vulnerability. But, as the infrastructure for charging stations develops, and as the number of charging stations increases, the infrastructure itself must include strong cybersecurity protections. Not only are the vehicles themselves at risk, but so too are home networks, cloud and electronic connections, and anything else connected to the internet.
Despite the progress of technological development in electrified powertrains and solutions for infrastructure needs, and despite the emerging industry partnerships and collaboration between private and public entities, one main challenge is consumer adoption of electrification. One industry that is a key indicator of adoption is the automotive industry. Lately, we’ve seen multiple automakers rollback their strategies for an electrified portfolio, cut current production of electric vehicles, and even shift their vehicle portfolio focus to the extension of existing high-volume vehicle platforms using traditional gas-power powertrains. The supply chain also continues to be disrupted based on contracted volume reductions or the effects of full vehicle cancellations. The availability of usable materials at the necessary volumes is also an issue–conflict minerals and rare earth metals are in limited supply from unrestricted regions. Automakers have tried diligently to push electrified vehicles in this industry, but consumers have yet to fully embrace them.
This hesitancy may be based on obvious issues like incomplete charging infrastructure. It may also be based on concerns of the effects of cold and hot environments on vehicle usage. Or, it may be that some drivers still just love their ’69 Mustang or, like me, their Ram 2500 diesel. Whatever the issue, adoption in the automotive industry is a consumer-driven challenge that, until it is overcome, will likely prevent the full implementation of electric vehicles as an alternative to traditional powertrains.
But, as I said, the automotive industry is not the only industry where electrification is happening. In other industries, electrification is being adopted by the consumer or user at a much higher rate. Electric scooters as personal transportation solutions are prevalent. Rail and bus systems with on-the-go or fast-charge pitstop charging solutions are becoming more and more prevalent. Certainly, last mile delivery services are adopting electrified solutions. As cybersecurity issues are addressed, as battery technology and charging infrastructure solutions are developed in these industries, and as consumers become more acquainted with electrification, the hurdles will be slowly knocked down and the opportunity for more wide-spread adoption increases. To accomplish widespread adoption, collaboration is needed from all stakeholders. Industry leaders are aware of this, and they are certainly leading the "charge."
WIRED FOR CHANGE: Electrification and the Future of Mobility
When it comes to mobility, one thing seems certain: electric vehicles will play a major role. Over 30 countries passed 5% Electric Vehicle (EV) adoption in 2024. If that does not seem significant, Bloomberg predicts this is the innovative technology threshold that historically signals an impending mass adoption. In the U.S., electric vehicles comprise 8% of new auto sales at around 300,000 cars.
With concerns about climate change and air pollution increasing, governments around the world are pushing for a shift towards cleaner transportation options. And with advancements in technology and decreasing costs, electric vehicles are becoming more accessible and practical for the average consumer.
“We looked at examples and use cases where electrification is playing a role: Aircraft and hovercraft mobility, the mobile machine market, delivery and logistics trucks, e-bikes and scooters, and even the defense market are all being electrified,” said Michael Brooks, Phoenix Contact Market Segment Manager of eMobility.
However, the shift toward electrification is not without challenges. Electrification infrastructure, EV capabilities and consumer adoption and appropriate policy remain key hurdles to seeing the benefits of a more sustainable and electric future.
EV and Hydrogen Trends
Lithium-ion batteries are one of the most used battery technologies in EVs, offering high energy density and allowing for longer driving ranges. For consumers, prices continue to fall for lithium-ion battery packs, making EV production cheaper.
However, lithium-ion batteries rely on a complicated supply chain. For years, China dominated the market in securing raw materials and extraction, creating an oversupply in batteries. But a recent Bloomberg study shows Canada holds the cards globally for a long-term and healthy lithium-ion supply chain due to its integration with the U.S. automotive supply chain.
Yet, lithium-ion is not the only kid on the block when it comes to sustainable transportation.
“Industry may consider exploring hydrogen and fuel cells as an alternative to electrification,” said Mitchell Zajac, Butzel Shareholder and Automotive Specialist.
Hydrogen-powered transportation was first conceptualized in the early 1800s and tinkered with by scientists and automobile manufacturers in the mid-20th century. However, due to high costs and infrastructure limitations, it did not gain much traction.
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Modern-day solutions make it easier to produce, store, and transport hydrogen, opening opportunities for widespread use in transportation. Honda recently announced its first-ever hydrogen-powered vehicle, which is set to be the first of its kind in the American consumer market.
With the accelerating development of alternative mobility solutions, the ICE supply chain must reconcile and diversify looking toward the future. The time to pivot and reinvest is now.
Challenges and Progress in EV Adoption
There is certainly an appetite for electric vehicles in today's consumer market, with sales reaching a market share of over 7.6% in 2023. Numbers show that interest in EVs has increased over recent years as well. By 2030, roughly 40% of cars bought in the U.S. will be powered by electricity.
The challenge of fully realizing this adoption lies in buyer and broader market hesitancy. Like any new technological wave, electrification will require serious investments to get off the ground.
Modern-day solutions make it easier to produce, store, and transport hydrogen, opening opportunities for widespread use in transportation.
“Based on industry feedback, the biggest challenge with electrification is infrastructure, whether at a macro level or a micro level,” said Zajac. “For example, what are the effects on a small community if everyone charges overnight?”
“The implementation of local vs. state rules for electrification requires political solutions, including cooperation with local, state and federal governments,” Zajac added.
This encompasses everything from infrastructure to product development. The more resources there are for electric vehicles, the more comfortable consumers will be choosing one as their next car. Similarly, the greater the buy-in, the better-positioned manufacturers will be to innovate and lower prices.
As it stands, EVs are perceived as "the costlier option" for most American households. A Car and Driver study that lasted three years attempted to decipher the actual cost comparison between ICE and EV ownership, finding although EVs are pricier upfront, they provide more savings once three years elapsed, even without a federal tax credit for owning an EV factored in. For cost comparisons between specific makes and models, the U.S. Department of Energy provides a Vehicle Cost Calculator to aid consumers in deciding.
“Challenges include cost, weight, and charging distance. There are efficiency losses due to temperature and driving habits. Utilities face challenges, and there is a lack of infrastructure,” Brooks added.
New Initiatives Designed to Spur Electric Innovation
President Joe Biden's Inflation Reduction Act (IRA) provided a big step forward in America's journey toward electrification by provisioning several investments in the development and commercialization of EVs. Roughly $47 billion was set aside for the green technology, part of a greater $369 billion allotment towards “confronting the existential threat of the climate crisis". The Department of Transportation (DOT), the Department of Energy (DOE), and the Environmental Protection Agency (EPA) are administering several programs designed to direct funding where it is needed most.
For consumers, the most meaningful of these is a rebate for select allelectric and plug-in hybrid vehicles. Qualifying models are eligible for a $3,700 to $7,500 federal tax credit in addition to the incentives many state-level governments already offer. That brings the purchase price of an average EV within much closer reach of everyday buyers' budgets.
The IRA made several investments in the department of infrastructure, too. Over $20 million is going to fund 32 EV charging network projects at 33 federal buildings across 21 states. Eventually, 782 ports will be added to the federal government's electric vehicle fleet, which is a major step forward in promoting adoption on a national level.
In addition, the Discretionary Grant Program for Charging and Fueling Infrastructure (CFI) provides states, local governments, tribes, territories, and city planners another $2.5 billion in grants to finance the construction of electric charging infrastructure.
Sustainable and Renewable Energy Sources
Environmental sustainability is among the primary reasons why EVs were created in the first place. Especially if they are paying more, today's drivers want to know that their investment in an electric car holds meaning for the planet's welfare. Is it more Earth-friendly than owning one that runs on internal combustion? Certainly. However, some are beginning to ask whether EVs are the solve-all solution they are made out to be. These vehicles are only as environmentally sustainable as the companies that manufacture them are diligent.
Manufacturing EV Batteries
Batteries require a significant number of raw metals and minerals ranging from lithium to nickel. These resources must be mined from the Earth, refined, and eventually combined to create the power units that keep electric cars moving. Some are in short supply, while others are sourced from countries with questionable ethical and environmental standards.
“A big question in development is whether it's being led in the U.S. or overseas,” said Zajac. “Should we US stakeholders do more to encourage development here?”
The idea of deep-sea mining has been floated as a potential solution to on-land shortages, but the process itself poses significant risks to marine life and ocean ecosystems.
“In terms of battery technology, many stakeholders are pursuing various technology options, such as dual chemistry batteries or new ways of energy storage,” said Zajac. “Lower costs facilitate more adoption and acceptance by end-users, government, and businesses.”
Consumers have little insight into where the materials that go into making their EVs come from, putting the onus on car companies to be transparent about their supply chains. The problem is that not every profit-making company is eager to disclose how it stays competitive. There are valid concerns that some may cut corners to keep costs down and maintain their bottom line.
Brooks said industry wants to see more inductive charging technology.
“Battery chemistry is a frontier, where increasing charge and range is key. Integration of sustainable energy sources and battery recycling is essential, as recycled batteries can be repurposed for solar energy storage. Combining hydrolyzer technology and batteries offers further potential," he said.
Recycling programs, government oversight, and public pressure will all play an important role in ensuring the production and distribution of EVs remains ethical and sustainable. Luckily, several manufacturers are already investing in sustainable practices, such as Tesla's efforts to use recycled materials in their cars and Toyota's commitment to sourcing ethical metals for their batteries.
Renewable Energy Charging
Beyond the manufacturing process, there is also the question of where the electricity that powers EVs comes from. You might argue that it is just as bad to drive one if its main source of energy is a coal plant, of which there are still 216 in the United States. Most cities are still powered at least in part by non-renewable sources of energy like natural gas and petroleum. Many regions have plans to transition away from fossil fuels, but a complete switch seems far away since renewable energy currently only accounts for 20% of U.S. electricity supply. Further investments - like those made through the IRA and similar bills - will be critical to making both electric cars and communities as environmentally friendly as they can be.
Final Thoughts
The road to widespread EV adoption is paved with both challenges and opportunities. As governments and companies push forward with new initiatives, technological advancements, and policy changes, the future of electric vehicles looks promising. Despite the hurdles in infrastructure, manufacturing practices, and consumer acceptance, the momentum towards a more sustainable and electrified transportation system is undeniable. With continued investment in clean energy, ethical sourcing, and consumer education, electric vehicles have the potential to transform not just how we travel, but also how we interact with our environment. The journey is complex, but the destination—a greener, more sustainable future—is within reach.
Recommendations for Industry
As governments worldwide set target dates to transition away from fossil fuels, substantial opportunities exist to build electric vehicles, manufacture parts, and develop infrastructure for the automation and production industries. To situate themselves in a strong market position, industry leaders must embrace electrification as a strategic imperative, foster a culture of innovation and crossindustry collaboration, and prioritize sustainability and environmental stewardship
Electrification as a strategic imperative
To capitalize on the growth of EV sales, automakers, suppliers, parts manufacturers, and other related industry leaders must develop a wellplanned strategy to improve their positions in the market. Developing a successful strategy begins with knowing where to focus research.
Knowing the market — Conduct research to recognize which vehicles are in demand in various markets while monitoring sales outlooks for five, ten years, and longer.
Knowing the product — EVs and related technologies are complicated, and extensive knowledge and training are required to build a successful product.
Knowing your workforce — Determine who has the skills to work with EVs and who needs training on the latest technologies and innovations. Understanding shortfalls will determine hiring needs.
Knowing the cost — Estimate all financial expenditures before adding products, including equipment and facility upgrades, marketing expenses, employee training, parts costs, and supply chain changes.
Knowing the supply chain — Who supplies the parts and materials? Where are the metals sourced? Where are they shipped from? What are the potential breakdowns in the distribution chains? These questions must be answered.
Knowing government laws, regulations, and tax incentives — Federal, state, and local governments have different policies regarding EVs. A company should consider hiring well-versed personnel in urban planning, building codes, and public infrastructure initiatives. Don't overlook the value of tax experts, as millions of dollars in government subsidies and incentives are available for private businesses.
Knowing the customer — The most important consideration is how EVs will sell. Parts manufacturers must build relationships with vehicle companies to understand and meet their demands. Automakers must identify what their customers want to drive and address concerns such as sticker price, repair costs, range anxiety, and the availability of charging stations.
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A culture of innovation and cross-industry collaboration
The innovation behind more powerful batteries and faster charging times has stimulated EV sales growth. Despite vast technological improvements over the past decades, consumers still have some trepidation.
According to a November 2023 survey conducted by the AAA Newsroom, “One in four U.S adults say they would be ‘very likely’ or ‘likely’ to buy an electric vehicle (powered exclusively by electricity, i.e. not a hybrid) the next time they are in the market for a new or used vehicle …”
Other data gathered included:
● 76% of those interested cited a desire to save on fuel, while 60% wanted to purchase out of concern for the environment.
● The percentages for those likely to buy fully electric vehicles are Millennials (31%), Generation X (21%), and Baby Boomers (18%).
● 58% of potential buyers are likely to purchase a new EV.
The survey also collected data on reasons why consumers are apprehensive about buying an EV, which included:
● Cost of vehicle (59%).
● Lack of charging stations (56%)
● Replacing or repairing the battery (55%)
● Range anxiety (53%)
● In addition, four in ten were concerned about the impact of cold weather on an EV's range.
As improvements continue within the mobility industry, it is imperative to inform the public about the increase in the distance EVs can travel and the increase in places to charge them.
These numbers tell automakers there is a current and future market for EVs, but more work is needed to overcome some consumers' concerns, and innovation can provide the answer. Entrepreneur offers ways to create an innovation culture that will benefit companies:
Empower employees — Cultures that empower employees will recognize workers' contributions, even for simple ideas, welcome input in the appropriate setting, and reward risk-taking, even if results are not as hoped.
Embrace a culture of upskilling — The concept of upskilling describes a culture that develops employee capabilities and employability by instilling the knowledge, skills, and attitude workers need to improve job performance.
Adapt quickly to lead change — To innovate successfully, businesses need to stay nimble. Though following policies and procedures remains key to company values, leaders should react thoughtfully but act quickly in response to changing conditions.
Provide constructive feedback — Innovation does not typically strike by lightning. Instead, innovation occurs when employees receive on-thespot feedback, prompting them to find a creative solution.
Encourage open communication — For employees to exchange ideas, the lines of communication need to stay open, both between leadership and workforce and between workers themselves. Both internal and external communication should strike a consistent tone that celebrates initiative and innovation.
Gaining the consumers' confidence will take a collaborative effort because one industry cannot solve each concern alone. Automakers can make lighter vehicles that will travel farther on a single charge, but partnering with battery companies will allow for innovations that will improve overall performance and reliability. EV parts manufacturers have a place in the collaboration to offer insights into designing EVs that will either be compatible with current parts or require re-designs. Natural resource companies need to be a part of the collaboration to see if the materials are available to make large-scale changes.
Building a better charging station network that satisfies the needs across the U.S. requires a great deal of input from several industries, including automotive, electrical engineering, construction, public utilities, and urban planning. Other businesses and organizations, including multi-unit housing, auto dealerships, non-profit groups, school campuses, truck stops, gas stations, parking structures, restaurants, hotels, and city parks, are joining the effort by hosting charging stations.
As improvements continue within the mobility industry, it is imperative to inform the public about the increase in the distance EVs can travel and the increase in places to charge them. That's where marketing firms join the collaboration. Informative ad campaigns and public service announcements will address how industries came together to alleviate the anxieties of purchasing an EV.
Prioritize sustainability and environmental stewardship
Electric vehicles are better for the environment, which is important for many potential buyers. The 2023 AAA Newsroom survey stated concern for the environment (60%) as the second most prevalent reason consumers would purchase an EV, trailing only gas savings (76%).
While EVs do not emit greenhouse gasses and reduce air pollution compared to gas-powered vehicles, they are not 100% carbon-free. Manufacturing EVs require energy, and making lithium batteries is a significant source of that usage. According to MIT, the use of minerals including lithium, cobalt, and nickel, which are crucial for modern EV batteries, requires using fossil fuels to mine those materials and heat them to high temperatures. “As a result, building the 80 kWh lithium-ion battery found in a Tesla Model 3 creates between 2.5 and 16 metric tons of CO2.” This means that building an EV can produce about 80% more emissions than building a comparable gas-powered car.
However, the overall reduction in carbon emissions comes from the time an EV spends on the road. The energy used to charge batteries varies from coal-burning to wind power, solar, and hydroelectric. Statistics from the U.S. Department of Energy point out that "EVs create 3,932 lbs. of CO2 equivalent per year, compared to 5,772 lbs. for plug-in hybrids, 6,258 lbs. for typical hybrids, and 11,435 lbs. for gasoline vehicles." The DOE report said that in places such as West Virginia, where coal-heavy energy plants create electricity, EVs emit less carbon than gas-powered vehicles.
Making EV batteries more environmentally friendly requires making them smaller to reduce the materials needed to build them and developing alternative chemistries that move away from lithium, which is currently the most popular type of battery used in the U.S.
Among the alternatives are sodium, magnesium, seawater, glass, and fuel cells.
Recycling these batteries is an essential part of helping the environment. Most EVs in the U.S. are newer and have yet to reach the point where they need to be recycled. The U.S. Department of Energy says that “separating the different kinds of battery materials is often a stumbling block in recovering high-value materials. Therefore, battery design that considers disassembly and recycling is important in order for electric-drive vehicles to succeed from a sustainability standpoint." The DOE went on to suggest “standardizing batteries, materials, and cell design” to make the process simpler and “more cost-effective.”
Automakers and battery manufacturers preserving the environment are important to customers when considering purchasing an EV, and they know the high cost and resources that go into electric batteries, so it is in these companies' best interests to form cross-industry collaboration to unleash new technologies that create better sustainability.
Another aspect of sustainability is to extract the resources needed for EV batteries in a more environmentally-friendly way. But discovery of new resources requires expert knowledge on where lithium resides on the earth's surface and how it is concentrated, according to the U.S. Department of Energy. Materials used in these batteries such as cobalt, nickel, and lithium are all extracted using environmentally-damaging methods. Nearly 500,000 gallons of water are used to extract one ton of lithium.
Inside the lithium-ion car batteries
Recommendations for Academia
Electric vehicles will open up a diverse array of career opportunities, spanning from the initial sourcing of materials to the final stages of sales and support.
As the target dates for creating an all-electric fleet of vehicles get closer, the next wave of innovators is in high demand, and academic institutions are crucial to preparing future industry leaders to help meet those deadlines. Academia must identify the necessary areas of study, lead research and development, and foster interdisciplinary collaboration within its institutions to properly prepare the EV workforce.
Identify Necessary Areas of Study
Electric vehicles (EVs) will open up a diverse array of career opportunities, spanning from the initial sourcing of materials to the final stages of sales and support. The US Bureau of Labor Statistics has provided a comprehensive list of careers that highlight where academic institutions can focus their curricula to effectively meet the evolving workforce needs of the EV industry.
● Scientific research: Chemists and materials scientists conduct research to increase battery life and reduce charging time while exploring the use of new materials in EV production.
● Design and development: An influx of engineers, technicians, software developers, mathematicians, and industrial designers is needed to create, test, and integrate new technology into EVs and the grid.
● Manufacturing: With millions of EVs expected to hit the road over the next several decades, a large workforce trained in the technical skills necessary to build complex vehicles is required.
● Maintenance: All vehicles require maintenance and repairs, and EVs are no exception. Traditional mechanics can perform routine work, but the electrical systems and drive trains are more complicated and require specialized training. Battery repair and installation also require specific skills.
● Infrastructure development: Plug-in hybrids and EVs need places to charge and workers to install charging stations in homes and public spaces, which means vast changes to the existing infrastructure. Workers capable of installing the hardware will be in demand, but so will urban planners, logistic experts, private industry, and government officials capable of navigating multiple municipalities and states' regulations regarding integrating into a national grid.
● Sales and support: Only some careers in the EV field will be handson. Some will require workers capable of explaining the processes and tax incentives to customers before and after purchasing an EV. These workers must have extensive knowledge of how the technology works, how it meets customers' needs and government regulations.
Research and Development
Higher education is at the forefront of the EV transition, and significant investments are being made in EV R&D. The University of Michigan's Electric Vehicle Center, with an estimated cost of $130 million, will focus on cutting-edge research and development, workforce training programs, and infrastructure building. Similarly, the University of Tennessee's EV Center, projected to cost around $160 million, aims to achieve comparable goals. These centers will join a growing number of higher education institutions dedicated to EV and battery innovations. There are many other research and development initiatives on college campuses, further emphasizing the critical role academia plays in advancing EV technology. Here’s a look into some of the other EV R&D programs nationally. These projects are essential because the innovations have real-world applications, improve industry efficiency, and help achieve EV production goals designed to alleviate climate change.
● The University of Texas is working on a lithium-ion battery that doesn't use cobalt as a cathode. Instead, it uses up to 89% nickel, aluminum, and manganese. The motivation is that cobalt is rare, expensive, and harmful to source from the environment.
● The University of Eastern Finland has developed a method to produce a hybrid anode that uses mesoporous silicon microparticles and carbon nanotubes. They hope to replace graphite as the anode with silicon, which has ten times the capacity. Silicone sourced from barley husk ash is earth-friendly.
● The University of California Riverside is developing a battery that uses sand to create pure silicon to increase performance and lifespan.
● The University of California is working on nanowire batteries that will never die. The gold nanowires are a thousand times thinner than human hair and sit in a gel of electrolytes to keep them from breaking down during recharging. They have been tested recharging over 200,000 times over three months and showed no sign of degradation.
Foster Interdisciplinary Collaboration
Solving the EV puzzle will require significant collaboration between departments at academic institutions. While the need for engineers, computer programmers, chemists, technicians, and materials scientists is crucial to a smooth transition, so are urban planners, environmental scientists, public policy specialists, marketing majors, and behavioral experts. Working together will provide the best outcomes and spark innvoation.
As academia continues to train quality workers who will build EVs and related infrastructure, resources must be committed to surpassing the societal barriers to the new technology.
● Urban planners will determine where to build factories, develop the charging station network, and ensure equitable technology distribution into underserved communities.
● Environmental scientists are needed to determine the climate impact of new factories and infrastructure on the surrounding ecosystem.
● With every new factory, public charging station, and home charger, public policy specialists guide federal, state, and local government policies, regulations, and tax incentives. This knowledge becomes increasingly valuable as various government bodies collaborate to build a national charging network.
● Marketing the vehicles and continuing to educate consumers on constantly updated technology is critical to making the rollout of EVs a financial success. The people behind the ad champions, media outreach, and product information presented on a company's website must fully understand the technology and how it benefits the purchaser.
● Switching to all-electric vehicles requires a change in habits deeply ingrained in society. There will be resistance to adopting the new technology, and behavioral experts offer insights into how the various cohort groups will react to the changes and best practices for smoothing out the transition's difficulties.
Academia Meeting the Needs of Industry for EVs
In the United States, the world's No. 2 auto market after China, EV sales growth has trailed Europe's, and the Bureau of Labor Statistics predicts around 80,000 electrician jobs will be needed annually through 2031, which includes technicians to fix EVs or install EV chargers. To meet those needs, academia can:
● Promote interest among middle school and high school students
● Develop mentorships/internships
● Update high school curriculum to include EV and battery repair
● Create post-graduate programs that expedite certification
● Work with the auto repair industry to reskill workers
● Seek government grants and private donations to create scholarship opportunities
Recommendations for Government
The United States government has set a goal to make half of all new vehicles sold in the US in 2030 zero-emissions vehicles, and to build a convenient and equitable network of 500,000 chargers to help make EVs accessible to all Americans for local and longdistance trips.
Converting fossil fuel-dependent vehicles to electricity is a massive undertaking, and governments can help accelerate the transition to a more eco-friendly fleet of automobiles. The United States government has set a goal to make half of all new vehicles sold in the US in 2030 zero-emissions vehicles, and to build a convenient and equitable network of 500,000 chargers to help make EVs accessible to all Americans for local and long-distance trips. To achieve that benchmark, the federal government must establish regulatory policies, invest in infrastructure and public transit, and facilitate public-private partnerships
Regulatory Policies
The US EV initiatives include policies directed toward its agencies. In 2021, President Joe Biden issued an Executive Order requiring the federal government to purchase zero-emission vehicles (ZEVs) by 2035, including 100% light-duty vehicle acquisitions beginning in 2027. The executive order affects about 380,000 vehicles.
In a July 2023 report by the Government Accountability Office (GAO), "Most of the 30 affected agencies have started preparing their workforces and set annual goals for installing charging equipment and acquiring vehicles. In the 2023 fiscal year, 26 agencies set a target to install 8,500 charging ports and acquire nearly 9,500 zero-emission vehicles."
The GAO conducted a study of federal agencies that revealed a lack of understanding of new technologies can hinder the transition to ZEVs. Training initiatives, pilot programs, small-scale rollouts, and demonstrations are used to familiarize federal employees with the technology.
Individual states are also pushing the move to ZEVs as well. Michigan Gov. Gretchen Whitmer signed an Executive Directive with mandates similar to the federal initiatives. The state has begun converting its fleet to ZEVs to replace all light-duty vehicles by 2033 and medium- and heavy-duty by 2040. According to government-fleet.com, the directive prioritizes cars that travel the most miles and are in use in Justice40 communities, which are high-density areas that higher pollution levels have impacted.
California went beyond regulations regarding its government fleet by mandating that 35% of new cars sold in the state will be hydrogen fuel cell, plug-in hybrid, or electric by 2027, 68% by 2030, and 100% by 2035. Continued on next page
Infrastructure and Public Transit
2023 saw the highest sales of new EVs in the US with 1.2 million battery electric vehicles and 190,000 plug-in hybrids totaling 1.36 million vehicles, which is 8.8% of the 15.5 million sold. The article projects the total number of new EVs could hit $1.9 in 2024.
All-electric public transit commuter buses made up approximately 3%1,873 in total - of nearly 61,000 of such vehicles in 2022, the most recently released data from the Federal Transit Administration, according to a December 2023 article on govtech.com, which lags behind the percentage of privately owned electric cars and trucks.
Federal grants are available to state and local governments to purchase electric buses, upgrade associated facilities, and train existing workers on the proper use and maintenance of the vehicles to help increase the number of electric buses.
As more EVs make their way to the roadways, developing a more robust charging station network is crucial. According to a February 2024 Consumers Affairs report, there were 64,187 EV charging stations across the US, a 20% increase over the prior year, with a 22% year-to-year jump in public changing outlets to 175,575. Five states account for 46.4% of those stations, so achieving equitable technology distribution is imperative.
Meeting the Federal Government's goal of installing 500,000 stations and distributing them to the states with the most need by 2030 requires substantial funds and resources. To address some of the financial needs, the Department of Energy is offering several research and development grants for the improvement of electric batteries and charging stations.
The Inflation Reduction Act of 2022 included “$5 billion to build out a network of EV charging along highways (alternative fuel corridors) and provided another $2.5 billion in competitive grant funding to further build out charging infrastructure (though this includes all alternative fueled charging technologies). At least 50% of the funding under the competitive grant program must be put towards communities, with priority given to lowincome and rural communities.”
States are stepping up as well to help achieve the national EV charging station network goal with initiatives such as Michigan's Electrification Technology Grants, which provides funds to mobility and electrification companies to deploy their technology in the state, and the Charge Up Michigan Placement Project, which provides funding for public or private organization for the installation of direct current fast charging stations, site preparation, and networking fees and signage.
Public-private Partnerships
Getting more EVs on the road and installing places to charge them face several challenges. Government and industry leaders working together can overcome these challenges.
The US Federal Government currently offers several loans and tax incentives for Advanced Technology Vehicles, including electric vehicles, which benefit manufacturers and consumers.
Businesses can borrow up to 30% of the cost to restructure facilities to accommodate EVS, and consumers are eligible for tax relief when purchasing an eligible vehicle. There are also government-funded technology grants designed to encourage improving EV battery technology.
The government can play a role in fostering partnerships to develop the infrastructure needed to keep the ever-growing fleet of EVs charged and on the road. In February of 2023, the White House released a statement about companies in related industries coming together to build a reliable nationwide charging network. For example, one such collaboration featured Pilot Company, General Motors, and EVgo's plan to build a coast-to-coast network of 2,000 high-power 350 kW fast-charging stalls at Pilot and Flying J travel centers nationwide. Other companies such as Ford, Hertz, BP, Tesla, TravelCenters of America, Electrify America, Francis Energy, and Forum Mobility also announced plans to add charging outlets to the nationwide network.
Restructuring production facilities, building more EVs, and installing more charging stalls require industry leaders to understand federal, state, and local regulations regarding tax incentives, building codes, parking, zoning, and building permits. These regulations can vary greatly between municipalities, so good communication between governments and the private sector is essential during the planning phases of these multi-million dollar projects.
Other Considerations
Battery Technology Improvements
To battle range anxiety, automakers must reassure buyers that their EVs can travel long distances and powered by durable, long-lasting batteries that charge quickly. All-electric vehicles can typically go between 110 and 300 miles on a single charge. They can take anywhere from a couple of hours to 40, depending on the size of the battery and charging outlet, according to the US Department of Energy. Most EVs come with a 110-volt (Level 1) cordset that can be plugged into a typical household outlet and takes about 40 hours to an EV to 80%. For quicker charging, homeowners can install a 240-volt (Level 2) and cut that time to about four to 10 hours. Direct Current Fast Charging can achieve 80% charge in 20 minutes to one hour.
The race for better electric car batteries is being called the next gold rush, and there are many new technologies coming that may make it easier to own and run a zero-emission vehicle, including nanotube electrodes that would increase power, cobalt-free batteries that are cheaper to produce, replacing unstable silicon in lithium-ion batteries with silicon anode to improve performance, using sand to create pure silicon to increase lifespan, and using seawater to replace hard metals and speed up the changing process. Research is also underway to use Wi-Fi and over-the-air ultrasound charging, along with biological semiconductors used in chargers by StoreDot, a start-up company that is producing EV batteries that charge in five minutes and have a range of 300 miles.
Grid Integration
Getting millions of private charging stations on the grid is a monumental undertaking, and the National Renewable Energy Laboratory is helping to make that happen. The Laboratory's goal is to transform "energy through research, development, commercialization, and deployment of renewable energy and energy efficiency technologies.”
The organization is currently developing hardware solutions to integrate EV charging in homes, multi-unit dwellings, workplaces, and privately owned buildings on the grid. NREL collects data on driver usage and battery life to research energy requirements for large-scale buildings and maintain and optimize their electrical infrastructure.
Making 100% of all passenger vehicles electric by 2050, one crucial question: Can the grid handle it? According to research published by Consumer Reports in May of 2023, the answer is "Yes." The report offered the following analysis:
“Americans drive approximately 2.9 trillion miles a year, and the average efficiency of the top 20 EVs is 3.1 miles per kilowatt hour. Dividing these two numbers, we find that if we were to instantly convert every passenger vehicle in the US to a battery electric vehicle, we would need to generate an additional 950 billion kilowatt hours of electricity per year. If we divide that number by the 4.2 trillion kilowatt hours that are currently generated in the US, we find that electrifying the entire fleet would require a 22% increase in total electricity generation.”
Range Anxiety
EV Range Anxiety is the fear that a vehicle will not have enough charge to reach its destination. That fear becomes more pronounced with longer travel distances, especially in rural areas. Some of that fear may be relieved with the development of more efficient batteries and an increased number of charging stations added to the network, but more can be done to ease the most anxious drivers. Nationalgrid.com offered the following suggestions:
• Electric vehicle apps. Download apps that plan the shortest route, estimate battery life, and offer to charge station locations.
• Be prepared. Make sure the EV is fully charged and that the final destination has home or public charging stations.
• Charge when stopped, not stop to charge. Be efficient with your time by taking any opportunities during your trip – such as coffee or bathroom breaks – to plug in and charge.
• Pay it forward. Being a thoughtful EV owner matters, too. If you see a charge point that isn't working, call it in and help resolve the problem as quickly as possible. Sometimes it takes just a matter of minutes, and the charge point will be ready for use soon.
INDUSTRY PULSE
Automation Alley posted weekly polls in March and April 2024 for our LinkedIn followers of over 6,000 professionals in the technology and manufacturing ecosystem on the topic of EVs and mobility. This is how the industry responded at a glance.
How fair is the EV market priced for the average US consumer?
Do you see hydrogen fuel cells as a viable option for the future? What
How prepared is the automotive manufacturing supply chain to pivot to EV production in comparison to ICE production?
KEY TAKEAWAYS
Significant Growth and Adoption
Over 30 countries surpassed 5% EV adoption in 2024, a threshold historically indicating mass adoption. In the U.S., EVs constitute 8% of new auto sales, driven by technological advancements and decreasing costs.
Challenges in Infrastructure and Adoption
Despite growing demand for cleaner transportation, challenges like electrification infrastructure, EV capabilities, consumer adoption, and appropriate policies persist. Addressing these hurdles is crucial for a sustainable electric future.
Sustainability and Ethical Sourcing
The sustainability of EVs hinges on the ethical sourcing and manufacturing of batteries, which require significant raw materials. Transparency in supply chains, government oversight, and public pressure are essential for maintaining ethical practices.
Strategic Imperatives for Industry Leaders
Industry leaders must develop strategies focusing on market research, product knowledge, workforce skills, financial planning, supply chain management, and regulatory compliance. These strategies will help companies improve their market positions and address consumer demands effectively.
Fostering Innovation and Collaboration
Innovation and cross-industry collaboration are crucial for advancing EV technology and addressing consumer concerns. Empowering employees, upskilling the workforce, and encouraging collaboration among automakers, battery companies, and parts manufacturers will drive technological advancements.
Prioritizing Sustainability and Environmental Stewardship
The US federal government aims for half of all new vehicles sold by 2030 to be zeroemissions, supported by a network of 500,000 chargers. Investments in infrastructure, including equitable distribution of charging stations and federal grants for electric buses and worker training, are essential for widespread EV adoption. 1 2 3 4 5 6 7
EV manufacturing, especially for batteries, generates significant carbon emissions. Reducing battery sizes, developing alternative chemistries, and improving recycling processes are key to sustainability. Cross-industry collaboration is necessary for more environmentally-friendly material extraction and sustainable practices.
Establishing Regulatory Policies and Investing in Infrastructure
ABOUT:
MISSION:
Automation Alley is a nonprofit technology business association and Digital Transformation Insight Center focused on driving the growth and success of businesses in Michigan and beyond through innovation and automation. With a global outlook and a regional focus, we foster a vibrant community of innovators, entrepreneurs, and business leaders through opportunities for collaboration and learning. Our programs and services help businesses develop the skills and expertise needed to effectively jumpstart or accelerate digital transformation. By bringing together industry, academia, and government, we aim to create a dynamic ecosystem that drives innovation and growth across Michigan.
At Automation Alley, our mission is to help businesses thrive in the rapidly changing digital economy. We equip them with the knowledge, insights, and tools to develop a software-first mindset that leverages the power of automation, AI, and other cognitive technologies. We believe that by working together, we can build a stronger, more innovative, and more competitive economy for the future.
Wealth, prosperity and equality through technology.
Publication Credits
Editorial: Nicole Kampe, Dennis Burck, Joseph Gray
Graphic Design: Laura Gearhart
Photography: Sean Healey
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