Like any other product, electric vehicles are made up of many components that are mined, manufactured, used, and eventually recycled or disposed of. Many focus purely on battery minerals or usage, but the full lifecycle is discussed less often. In this blog, we’ll discuss the three main phases of an EV lifecycle: manufacturing, usage, and end-of-life.
Phase 1: EV Manufacturing
Investopedia notes that the automotive sector “The sector uses more raw materials than just about any other industry. These include aluminum and glass, useful because it is lightweight and durable, and iron, which is converted into steel and employed for its strength and versatility. In addition, petroleum products aren't just used to power automobiles after production but are the basis for plastics, rubber, and specialized fibers found throughout cars.” The automotive supply chain is truly global, with numerous companies involved in mining, component manufacturing, and vehicle assembly.
To make EV batteries, car manufacturers rely on several different critical minerals, including lithium, cobalt, and nickel. Until relatively recently, the United States has been reliant on other countries for these minerals. However, there has been a push from the federal government to onshore the extraction and refining of these minerals, which promotes American jobs.
What about Cradle-to-Grave emissions?
Cradle-to-Grave emissions: Total emissions generated over the lifecycle of a vehicle, including mining, manufacturing, driving, and recycling.
Some critics of electric vehicles claim that because manufacturing an EV produces CO2, “electric vehicles are not truly zero-emission vehicles.” Recurrent points out that while manufacturing an EV requires more water and emits more CO2 than manufacturing a similar internal combustion engine (ICE) vehicle, automakers themselves are pushing for decarbonization in the supply chain. As more suppliers and automakers electrify their own processes and increase efficiency, the emissions from manufacturing an electric vehicle will decrease over time.
We’ll discuss a related topic, Well-to-Wheel emissions, in the next section.
Phase 2: EV Charging & Driving
EVs are powered via whatever type of electricity a charging station’s local grid uses. If a local grid uses primarily renewable energy sources, this makes your EV less carbon-intensive than one charged at a location where the electricity is primarily coal-based. However, regardless of how the electricity is produced, domestic power generation supports local energy jobs.
What about Well-to-Wheel emissions?
Well-to-Wheel emissions: All emissions related to producing fuel to move the wheels including extraction, refining/processing, distribution, and burning within an ICE engine to power the wheels. (Source: US Department of Energy)
The ”well” part of the phrase, “Well-to-Wheel Emissions,” refers to the way that energy is generated to power the vehicle’s wheels. While ICE vehicles are powered by oil, electric vehicles are powered by the energy source used by the charging station. Depending on your region, your EV may be powered by: coal, natural gas, solar, wind, hydroelectric (water), nuclear power, or other sources.
Compare these energy breakdowns from the US Department of Energy.
| Region | #1 Source | #2 Source | #3 Source | #4 Source |
|---|---|---|---|---|
| US (National) | 38.32% natural gas | 19.85% coal | 18.6% nuclear | 10.47% wind |
| Maryland | 38.95% nuclear | 36.22% natural gas | 12.18% coal | 4.84% solar |
| California | 40.04% natural gas | 29.03% solar | 8.42% nuclear | 8.02% hydro |
| Texas | 44.72% natural gas | 23.48% wind | 17.6% coal | 8.58% nuclear |
| Florida | 74.49% natural gas | 11.99% nuclear | 6.04% coal | 5.48% solar |
| Washington (state) | 68.23% hydro | 11.83% natural gas | 8.35% nuclear | 7.75% wind |
As shown above, your source of electricity varies depending on your local power generation. Find your state’s energy mix here.
EVs may start with a slightly higher manufacturing footprint, but they quickly surpass ICE vehicles in sustainability. Unlike ICE vehicles, which rely on burning fuel and emit tailpipe pollution, fully electric vehicles produce zero direct emissions when driving. Over their full lifecycle, EVs generate significantly lower CO₂ emissions—and their impact keeps getting cleaner as the power grid transitions from fossil fuels to clean, renewable energy like solar, wind, and hydropower.
EV efficiency
When it comes to the energy that vehicles produce themselves, EVs are more efficient than ICE vehicles. In fact, EVs convert over 77% of the energy they receive from the electricity grid to power their wheels, compared to ICE vehicles using just 12-30% of the potential energy stored in gasoline to power their wheels.
How to care for your EV battery
An EV battery can last as long as the vehicle’s lifespan, typically 10-20 years or 100,000-200,000 miles. Like all batteries, they will slowly degrade over time, losing around 1-2% of their range each year. However, unlike ICE vehicle batteries, EV batteries typically have a 10-year or 100,000-mile warranty that does not require a replacement every 2-3 years.
By caring for your battery properly and using strategic driving techniques, you can prolong your EV battery’s life.
To extend the life of your EV battery to its fullest:
Drive at consistent speeds as much as possible and avoid extreme acceleration and deceleration.
Charge with Level 2 EV charging stations whenever possible.
Avoid extreme heat in summer and extreme cold in winter as much as possible, especially when parking. Park in the shade or a garage when available.
Avoid letting your battery drain below 20% capacity.
Avoid charging your battery to 100%. (Maintaining a battery capacity of 20-80% is best and allows you to use regenerative braking features.)
Avoid immediately charging your battery after parking. Let your battery rest for a bit so it can cool down.
Refrain from charging every single night if you don’t need to charge.
Phase 3: EV End of Life
Eventually, all cars will be replaced. The average age of a vehicle was 12.6 years in 2024, though a Zebra survey found that the average American only keeps a vehicle for about 8 years (shorter than the typical EV battery warranty). Tech-oriented EV drivers who prefer to keep up with the latest technology may prefer to upgrade to the next EV model after just a few years, however.
When an EV’s battery falls to 70-75% of its initial capacity, you may expect to need a replacement. But thanks to advancements in EV battery recycling, both the batteries and vehicles can be disposed of responsibly.
There are now specialist companies that break down EV battery packs and reclaim the materials they contain, such as lithium, cobalt, manganese, and nickel.
Even with 25-30% of their capacity gone, old EV batteries can still hold much electrical energy, and there is potential for them to be used as part of the electrical grid for backup electrical storage or as part of a mini-grid.
The EV industry continues to strive to minimize the amount of waste it produces both at the beginning and the end of a vehicle’s lifespan.
Conclusion
From manufacturing to driving to resale or disposal, electric vehicles are an exciting new option for vehicle owners and lessees. Thinking of getting your first EV? Download the Blink Charging App to find your nearest charging station!