Green Car Journal logo
Kristina Fritz, California Hydrogen Business Council.
Katrina Fritz is Executive Director of the California Hydrogen Business Council.

In recent years, state energy and regulatory agencies have modeled plans that conclude hydrogen is required to achieve deep decarbonization targets. Air pollution continues to worsen across the U.S. with hydrogen and fuel cells seen as part of the answer. For example, as a one-to-one replacement for diesel powered vehicles, equipment, and generators, hydrogen fuel cells have significant potential to decrease the negative air quality impacts this diesel equipment causes and eliminate their carbon emissions.  

With California’s current grid reliability challenges and need for more power generation capacity – coupled with the state’s continuing “overdemand” – all energy and mobility solutions must be brought to bear. National Lab studies have demonstrated the grid infrastructure required to charge battery electric vehicles of all sizes. The use of fuel cell electric vehicles, fueled by hydrogen, avoid further compounding grid reliability challenges.  The California Air Resources Board recent Hydrogen Station Self-Sufficiency Report  determined that an additional $300 million investment in hydrogen infrastructure, coupled with existing incentives like the Low Carbon Fuel Standard,  would lead to financial self-sufficiency of a fuel cell electric vehicle and hydrogen station network by 2030, avoiding additional upgrade costs and strain on the grid.

At the federal level, the multi-billion-dollar commitment to hydrogen and fuel cell programs in the 2021 Infrastructure Investment and Job Act (IIJA) has spurred a flurry of planning, project development, and investment in the hydrogen sector. States in every U.S. region have expressed support for project applications to the $8 billion Department of Energy hydrogen hub program. The awarded hubs will showcase production of hydrogen, distribution and delivery infrastructure, and broad end uses of hydrogen and fuel cells in the electricity, industrial, and transportation sectors.

Strong Support for Hydrogen

States from California to New York to Texas are committing significant funding and resources to support the development of these hydrogen hubs. The DOE and other agencies are launching additional energy manufacturing, clean electricity, zero-emission vehicle, and goods movement programs funded by the IIJA to further support hydrogen use alongside other clean energy technologies. Project developers and investors are simultaneously seeking guidance on the use of tax credits for hydrogen and fuel cells that came from the Inflation Reduction Act of 2022.

Hydrogen fuel cell big rig truck.

On the passenger light-duty vehicle side, Toyota and Hyundai continue to sell Mirai and Nexo hydrogen fuel cell vehicles in California. There are now over 15,471  fuel cell electric cars sold and leased in the U.S. In February, Honda announced a joint venture with General Motors to deliver a new fuel cell system not only for its light-duty vehicles but also for use in heavy-duty trucks, stationary power generation, and construction equipment. In early 2022, BMW announced its continued commitment to develop hydrogen-powered fuel cell vehicles with on-road demonstration of the iX5 to begin in 2023. 

Traditional manufacturers of engines and heavy-duty vehicles are partnering with clean energy companies to rapidly bring fuel cell electric vehicles to market in high volume, heavily polluted transportation corridors, with the assistance of the Hybrid and Zero-Emission Truck and Bus Voucher Incentive Program.  Already, on-road testing of fuel cell systems and vehicles made by Ballard Power Systems, Cummins, Hyzon Motors, Nikola Motors, and Toyota is underway. Off-road, the Port of Long Beach is working with Toyota and FuelCell Energy using a fuel cell to generate power, heat, and hydrogen, the latter used to fuel Toyota equipment at the port and Toyota Mirai vehicles coming off the ship. Byproduct water from the fuel cell’s hydrogen production is used to wash the cars.

Off Road and Materials Handling

Hydrogen fuel cell mining truck.

Presently, the largest throughput of hydrogen is in the off-road and materials handling sectors. In creating the first commercially viable market for hydrogen fuel cell technology, Plug Power has deployed more than 60,000 fuel cell systems and over 200 fueling stations, more than anyone else in the world, and is the largest buyer of liquid hydrogen. Plug customers have completed more than 55 million hydrogen fills into forklifts and other material handling equipment used in warehouses, including those operated by companies like Amazon and Walmart, showing the economic value of fuel cell powered forklifts. Contributing to their increased productivity throughput are advantages like rapid hydrogen refueling and a smaller overall footprint than battery electric counterparts that require space for chargers.

The State of California is considering the level of support needed for the required hydrogen fueling infrastructure to service all on-road fuel cell electric vehicles. Documents from the Hydrogen Fuel Cell Partnership illustrate the fueling stations needed for light-duty passenger vehicles and heavy-duty trucks  that would create a refueling network for launching a self-sustaining market. This would serve to quickly decarbonize key transportation corridors and improve air quality in the urban, rural, and agricultural communities along these corridors.

Hydrogen Powers Clean Transit

Hydrogen fuel cell bus on street.

Public transit agencies have been operating or conducting real-world testing of hydrogen fuel cell buses in their fleets . Following operational bus trials, many agencies concluded that both battery and fuel cell electric buses are required. Among the benefits cited for fuel cell buses are lower operating costs, often due to avoiding the investment required for battery electric buses such as charging stations and the need to expand capacity at local electric substations. In addition, the longer range and greater power density of fuel cell electric vehicles can support transit operations that must deal with varied, hilly terrain and longer routes.

California currently has 66 fuel cell electric buses in service with another 100+ committed to be placed in operation. Many transit agencies are set to follow the pioneering efforts of Alameda-Contra Costa Transit and SunLine Transit with their fleets of fuel cell electric buses and hydrogen refueling infrastructure. Among these are California’s Foothill Transit, Orange County Transit, and Humboldt Transit. Outside California, Stark County Transit in Ohio and Southeastern Pennsylvania Transportation Authority (SEPTA) in Philadelphia are committed to using hydrogen fuel cell buses to meet their service needs.

Hydrogen is here. Debates on energy resources should include discussion of best fit, rather than either-or. There is significant public and private recognition across the U.S that an all-of-the-above strategy is needed to meet our varied energy requirements and decarbonization goals, and hydrogen is poised to make an immediate and growing contribution to a global decarbonization strategy.

Katrina Fritz is the Executive Director of the California Hydrogen Business Council (CHBC).

Illustration of Lexus steer-by-wire system.

There I was, doing my best to pilot a car around a test track in Sweden without the aid of a steering wheel. My job in this 1992 exercise: Negotiate the twists and turns ahead in an experimental Saab 9000 equipped with a steer-by-wire system and an aircraft-like sidestick controller, similar in concept to that used in Saab fighter jets like the JAS 39 Gripen.

The first few passes around the track were focused and intense, the car jinking far too actively in response to the inputs interpreted from my painstakingly measured efforts with the controller. I was clearly on unfamiliar ground here, quite literally and figuratively since this was my first time on this Swedish test track. But I was determined to get this right, and eventually I did, gaining a sense of the steering and confidently working the stick to turn into a curve, find the apex, and power out smoothly. Then my right-seat observer, a Saab tech with keyboard and display screen in front of him, adjusted sensitivity settings and the car was jinking again. Ahh…part of the learning process.

Lexus RZ Steer-by-Wire

Segue ahead some 30 years – quicker than Tom Cruise graduated from piloting Top Gun’s F-14 Tomcat to Top Gun: Maverick’s F/A-18E Super Hornet – and I’m in an auto-aircraft setting once again. This time I’m in the driver’s seat of an electric Lexus RZ test car equipped with advanced steer-by-wire technology, pondering the steering yoke in front of me.

Coming but not yet available, the steer-by-wire system in this Lexus was calling to me, offering an opportunity to pilot this car around a cone course where expectations were reasonably high that some of the orange pyramids ahead would be sacrificed to the cause, at least initially. But I was not about to repeat my experience with the sidestick controller those many years back, no sir. This would be different.

Lexus steer-by-wire steering yoke.

More Than Just a Yoke

Unlike Tesla’s addition of yoke steering in some Model S and Model X variants, a move that has reportedly caused some driver difficulties during tight turns, Lexus has given this much more thought and a serious dose of elegant engineering. For one, Lexus doesn’t just swap out a round steering wheel for a cooler-looking yoke. In a simple swap, a yoke makes tight turns requiring hand-over-hand steering more of a challenge. However, the yoke in an RZ is not simply a swap, but rather an integral part of a sophisticated steer-by-wire system.

In its steer-by-wire system, there is no mechanical connection at all between the yoke and the car’s rack and pinion steering. It’s all wiring and software backed up by triple redundancies. Software interprets steering input at the yoke and delivers this information to a motor controlling the pinion gear, steering the wheels. What’s important is that the system is speed sensitive and smart, providing a continuously variable steering ratio depending on driving conditions and inputs. The result is confident driving with much less steering wheel travel required than one might expect. Plus, no hand-over-hand steering needed ever, even during very tight turns. Driving this system did require dialing in to its operating nuances, but I figured this out quickly and no cones were harmed during testing.

Lexus RZ electric car.

Auto-Aircraft Tech

As I wrapped up this day’s steer-by-wire mission, I reflected on yet another auto-aircraft memory from years past. Back in the 1990s when GM introduced its swoopy, teardrop-shaped EV1 electric car, the automaker shared that the car’s groundbreaking 0.19 drag coefficient was the same as an F-16 Fighting Falcon, wheels down. The aircraft reference wasn’t surprising since GM had acquired Hughes Aircraft a few years earlier and the automaker was benefiting from a huge aircraft/aerospace brain trust. PR being what it is, we’re not sure if the F-16 aerodynamics comparison was actually accurate but it sure sounded impressive, and it gave us a good point of reference as to how slippery the EV1 really was during the time.

In the ever-changing realm of advanced vehicles and their affinity for aircraft and aerospace tech, what’s next on the agenda? I’ve already experienced Tesla’s “autopilot” and other automakers’ advanced driving tech so check that off the list, until newer iterations come to the fore. I have also driven blindfolded in a test environment during the early years of autonomous driving development…but that’s a story for another time. Maybe a flying car? I think I’ll wait on that.

Valerie Sarisky-Reed, Director of the U.S. Department of Energy Bioenergy Technologies Office.

The transportation sector is now the largest source of greenhouse gas (GHG) emissions in the United States, contributing to poor air quality and the climate crisis, and disproportionately impacting underserved and disadvantaged communities. To address this, our goal is to eliminate nearly all GHG emissions from the sector by 2050 while working to achieve a fair and just transportation system that will support economic growth and benefit all citizens.

In December 2022, the U.S. Department of Energy (DOE) joined forces with the Environmental Protection Agency, Department of Transportation (DOT), and the Department of Housing and Urban Development by signing and MOU to coordinate on transportation decarbonization. The first deliverable from that partnership was the January 2023 release of The U.S. National Blueprint for Transportation Decarbonization, a roadmap for how we can address these issues to provide better transportation and fuel options as well as zero-emission vehicles.

Light-duty vehicles (passenger cars, SUVs, pickup trucks, and motorcycles) are responsible for about half of all U.S. transportation GHG emissions. Medium- and heavy-duty vehicles (larger delivery trucks, work vans, and buses) are the second-largest contributor to transportation GHG emissions with 21 percent of all emissions. Aviation is the third largest contributor at 11 percent, including fuel used for all domestic flights and international flights departing the United States

Biofuel – derived from biomass or organic wastes – plays an important role in decarbonizing transportation. The Federal Aviation Administration projects continued growth for the aviation sector and as more EVs enter the market, aviation will become a larger portion of the transportation sector’s GHG emissions. 

Biofuels Support Decarbonization

To reduce aviation GHG emissions, the aviation sector is scaling up sustainable aviation fuel (SAF) use. SAF is a “drop-in” liquid hydrocarbon jet fuel produced from renewable or waste resources that is compatible with existing aircraft engines – a critical near-term solution to reduce GHGs. This led to the creation of the SAF Grand Challenge.

Commercial aircraft being refueled with low carbon biofuel.

Together, DOE, DOT, and the U.S. Department of Agriculture developed a roadmap to accelerate SAF research, development, demonstration, and deployment (RDD&D) to meet the ambitious government-wide commitment to accelerate production of SAF to 3 billion gallons per year by 2030 – ultimately meeting 100 percent of U.S. aviation fuel needs with SAF by 2050.

Scaleup Collapses the Timeline

DOE’s Bioenergy Technologies Office (BETO) supports RDD&D of technologies that convert domestic renewable carbon resources into biofuels and bioproducts. This effort is already decreasing the price of drop-in biofuels for airplanes, big rigs, and passenger vehicles. To meet the ambitious SAF Grand Challenge goals, BETO has accelerated efforts to scale up these technologies. Scale-up is essential for reducing risks associated with deploying novel technologies at large scale, as is expected in a biorefinery. In doing this, technologies move from the laboratory into relevant and realistic environments.

Developing low carbon biofuel to aid decarbonization.

Public–private partnerships are critical for ensuring that scaleup matches industry needs. For example, BETO is already funding projects with industry partners to turn industrial waste gases into jet fuel, convert biomass into refinery-ready biocrude, reduce GHG emissions from first-generation ethanol plants, and more. These large-scale pilot and demonstration projects enable researchers to test prototype components or subsystems in relevant operating environments. That way, researchers can identify further R&D needs for BETO’s subprograms. Large-scale projects also create larger volumes of target products, supporting quality control testing to verify existing infrastructure compatibility and potential end user specifications. They also provide data that analysts use to evaluate economic and sustainability performance.

Funding Spurs Innovation

BETO saw its first opportunity to fund SAF-focused research in 2021, awarding $64 million to 11 scaleup and demonstration projects. In early 2023, BETO awarded an additional $118 million to 17 projects with industry partners. In recognizing the need for strong designs prior to breaking ground on expensive construction, BETO requires projects to meet necessary criteria to advance from phase 1 into phase 2, which funds construction and operations.

By allocating funding across multiple years and different scales, BETO expects to collapse the time it takes to see success at the demonstration scale. Projects that meet criteria and are ready to go don’t have to wait years for additional opportunities.

As the demand for plane, train, and automobile transportation continues to increase, it is critical that we come together to find innovative solutions to the climate crisis. Biofuels can be a win-win solution, allowing our economy and way of life to thrive while lowering our carbon footprint on a national – and global – level.

Valerie Sarisky-Reed is Director of the U.S. Department of Energy Bioenergy Technologies Office

Steve Hornyak, chief commercial officer of BrightDrop.
Steve Hornyak, BrightDrop Chief Commercial Officer.

Perhaps the most well-known benefit of switching to an electric vehicle is the environmental impact due to the elimination of tailpipe emissions compared to an internal combustion engine (ICE) vehicle. But what isn’t as obvious is that they can also be less expensive over the operating lifecycle.

Why? For starters, we tend to focus on fuel prices, yet one thing that often gets overlooked is the reduced maintenance costs electric vehicles can offer. The U.S. Government's Office of Energy Efficiency and Renewable Energy estimates that scheduled maintenance costs for light-duty battery electric vehicles are about 6 cents per mile, compared to 10 cents per mile for a conventional vehicle. Someone buying a passenger car for private use is less likely to worry about maintenance, but for large fleet managers these cost savings can be meaningful over time.

Another costly issue for fleets is unscheduled repairs caused by breakdowns. According to the Deepview True Cost Second Owner Study by predictive analytics and data company We Predict, unplanned repair costs for electric commercial vans are on average 22 percent lower compared to internal combustion engine equivalents after three years on the road. The reason for this is that electric vehicles have fewer mechanical parts than internal combustion engine vehicles. This is significant because reductions in repairs also mean more time on the road for busy delivery fleets. In a world where downtime is death for fleets, keeping vehicles on the road is critical to meeting the ever-increasing demand for last-mile deliveries.

Charging BrightDrop electric delivery van.

Meanwhile, in March 2022, CNBC reported that diesel fuel was already costing over $5 (USD) per gallon nationally, with gasoline hitting $6 (USD) in some parts of the country. So there can be important fuel cost savings to be made for fleets that switch to electric vans. In fact, BrightDrop estimates fleet owners will save over $10,000 (USD) per vehicle per year in fuel and maintenance when switching to one of our Zevo 600 electric vans, compared to its diesel equivalent. Let’s take a closer look.

Fewer Moving Parts

Why do we expect electric vehicles will need less maintenance? Moving parts are a big part of it, because it’s the moving parts that most often encounter problems. Standard internal combustion engine vehicles usually have over 2,000 moving parts in the drivetrain, while electric vehicles tend only to have about 20. For example, a battery electric vehicle has no timing or fan belt and no alternator. Additionally, an electric vehicle also lacks many of the complex non-moving parts that often fail in internal combustion engines, such as oxygen sensors, spark plugs, and catalytic converters. A 2020 CarMD Vehicle Health Index assessment of the top 10 most popular car repairs in America found replacing a catalytic converter was the most common, while replacing an oxygen sensor came second. According to Forbes, only one of these top ten repairs could ever happen to an electric vehicle (and it was the cheapest to fix at $15). The lack of moving parts also means that repairs on electric vehicles can be less complicated.

Additionally, electric vehicles usually don’t use transmissions, meaning that the common (and expensive) issue of damage to gears is not an issue. Many electric vehicles also use regenerative braking to repurpose expended energy back into the batteries. In addition to electricity savings, regenerative braking can also increase the life (and therefore reduce spending on replacing) of conventional brake parts, due to minimal use. Finally, electric vehicles don’t use engine oil and, although they do use engine lubricants, these rarely require a refill or change.

BrightDrop is electrifying fleets for last mile delivery.

Advantages of Electrifying Fleets

Electric vehicles can be cheaper to maintain and repair than their ICE or diesel alternatives. They also can be kept on the road longer by reducing the frequency of unplanned repairs, as well as reducing the amount of labor that would otherwise be spent dealing with these problems. All of these benefits take time to accrue. They can only be realized if fleet managers take a ‘total cost of ownership’ perspective that considers all costs over the lifetime of a fleet.

Perhaps the biggest concern that electric vehicle buyers have is that the battery will degrade over time, ultimately requiring an expensive replacement. We believe that such concerns can be overhyped or misplaced. Battery range has improved markedly in recent years, and all BrightDrop vehicles adhere to or exceed federal regulations, which require that electric vehicle batteries are covered by warranty for a minimum of eight years or 100,000 miles, whichever comes first.

Now is the time to switch fleets to electric vans. It's an opportunity not only to help reduce vehicle emissions, but also to help realize potential cost savings.

Steve Hornyak is Chief Commercial Officer and Executive Director at BrightDrop

Dave Prusinski of Ford Pro.
David Prusinski, Ford Pro Intelligence

One trend we hear from the market is the challenge small and midsize organizations face in finding accessible, scalable fleet management software that works for their business across all powertrains, gas, hybrid, and electric inclusive. According to the U.S. Energy Information Administration, the global share of electric vehicles in a fleet is set to reach 31 percent by 2050. So, this challenge will continue in the years to come, especially as EVs become more widely adopted.

The reason? The market is awash with disintermediated software solutions, especially in the fleet management world.  Many large companies don’t have this issue as they have bigger budgets that acquire these solutions tailored specifically to them, or their in-house IT teams create bespoke solutions fit specifically for their business. This offers larger businesses a significant advantage in terms of efficiency. Smaller organizations typically lack the depth of IT support to integrate and customize disparate software solutions – let alone the capital to do so – to create integrated solutions that make their businesses safer, greener, and more efficient.

This is why there’s increased pressure on software vendors and OEMs to provide integrated suites of fleet management solutions to all, from Main Street USA to the largest fleets.

Organizations of all sizes need a simpler, integrated platform to enable holistic vehicle management, efficient maintenance monitoring with proactive scheduling. and improved driver behaviors to help increase the safety of operators while lowering costs associated with fuel, downtime, or vehicle damage. A single platform can also enable organizations to consolidate the management of their larger fleet needs, including managing vehicles across all powertrains as noted, as well as connectivity to insurance, financing, charging, and electric vehicle optimization. Adopting an integrated platform is essential for all businesses – and it represents a first step toward competitive parity for small and midsize fleets.

Man viewing Ford Pro telematics on computer screen.

Data Enhances Fleet Efficiency

Reaching the next level of efficiency and competitiveness is anyone’s game. As we’ve all heard, big data is the new oil that makes businesses run. One of the most critical applications of big data is the ability to reduce the total cost of ownership (TCO) and maximize the uptime of ICE vehicles and EVs.

Data helps organizations gain real-time insights into fleet operations to enable better decision-making and take proactive measures to ensure vehicles stay well maintained. Fleet managers are using data from connected vehicles to predict and prevent breakdowns in an incredible orchestration of activities that can drastically reduce vehicle downtime.

For example, let’s say my telematics system tells me I will soon need to replace a part in one of my vehicles. It will identify the exact part to be replaced and may also locate the part and have it shipped to my dealer. I can make an appointment with the dealer, where the vehicle will be off the road for a few hours or maybe a half day.

Contrast that to what typically happens, which is the late identification of an issue, taking the vehicle to the dealer, having them diagnose a problem, and then perhaps needing to order the part, waiting for the part, and then replacing it. This can take days instead of hours.

Electric Ford E-Transit and phone charging app enhances fleet efficiency.

The Future of Connected Vehicles

Data will also play a crucial role in deriving added value from connected vehicles. Once we have millions of cars on the road equipped with telematics, the amount of data generated will be massive. We’ll be able to use the data to monitor aspects of the vehicle – such as temperature, location, and brakes – and the surrounding environment. Through high-speed 5G connections, vehicles could contribute information to a giant data lake that, when analyzed in real-time, could provide information about the road ahead, traffic patterns, and potential hazards.

For example, suppose multiple vehicles report the use of anti-lock brakes and traction-control systems around a specific corner in a cold-temperature climate. In that case, analytics could infer there might be a patch of black ice and instruct other vehicles to slow down and take the turn carefully.

Or perhaps a deep pothole triggers connected vehicles’ sensors. A city could purchase data related to road issues and send crews out to make repairs before the issue causes damage to vehicles or injuries to passengers. The sensors could also help fleets prevent damage to expensive vehicles. Connected vehicles will and are using prognostics to diagnose and alert of potential catastrophic failures ahead of time.  

What Fleet Managers Should Do Now

To fully realize the benefit of connected vehicles, fleet managers must get their entire fleet connected. In the future, this will become easier as OEMs automatically embed modems in their vehicles. Companies like Ford Pro are already offering free solutions such as Ford Pro Telematics Essentials with their connected vehicles to help provide visibility into the health and performance of their vehicles.

The connected vehicle market is at a tipping point and is expected to grow rapidly in the coming years. This is good news for everyone: connected vehicles and integrated solutions can help small businesses achieve competitive parity, decrease costs through predictive maintenance, and apply analytics to reduce GHG emissions and maximize EV battery productivity to create a greener and more sustainable world.

David Prusinski is Global Chief Revenue Officer of Ford Pro Intelligence

Harjinder Bhade , CTO at Blink Charging.

As the country comes to the realization that a future of electrified mobility is crucial to mitigating the effects of climate change, government leaders and the electric vehicle (EV) industry have made it their mission to build a network of 500,000 EV chargers across America.

At the same time, the past year has demonstrated how disruptions in globally interconnected supply chains can lead to severe bottlenecks and slow production. The EV charging industry is not immune to these conditions. In order to achieve the ambitious electrification goals set by our elected officials and business leaders, EV charging companies must ramp up their domestic manufacturing capabilities to ensure they can meet the demand, regardless of global factors.

Meeting “Buy America” Requirements

There’s no better time than now to increase American manufacturing. With the Biden Administration’s Infrastructure Investment and Jobs Act (IIJA) earmarking $7.5 billion to build a nationwide charging network, there is more investment in the space than ever before. However, in order to qualify for these federal funds, EV charging manufacturers must meet the “Buy America” requirements – standards that call for equipment and projects to use American-made material and products, as well as be manufactured domestically. While domestic production of EV chargers holds much promise in solving supply chain concerns, this requirement also presents several challenges.

When considering the “Buy America” requirements for EV chargers, two provisions are most relevant. First, all steel in a finished product must be sourced locally. Secondly, under current criteria as clarifying language is pending, at least 55 percent of a finished product must come from the U.S.

Generally, meeting the steel requirement is not a challenge for EV charging manufacturers as chargers do not require large amounts of steel and steel can be locally sourced without undue burden. However, the larger challenge for EV charging manufacturers is sourcing domestically made chips, as most chip manufacturing is done offshore and imported to the U.S. From microprocessors to Wi-Fi and cellular modem chips, these necessary components are hard to source domestically, presenting a significant roadblock for EV charging manufacturers looking to meet the “Buy America” requirements.

Woman at Blink EV charger.

Manufacturing Corridors

In addition to the challenges presented by the “Buy America” requirements, there are also logistical challenges that come with relocating a manufacturing process, that was previously done overseas, entirely to the U.S.

In other countries, robust manufacturing corridors exist – areas of production where the various parts of a product are all sourced near one another – that help reduce the time and cost it takes to assemble critical components. However, in recent decades many of these components have been imported from overseas, and the U.S. has far fewer manufacturing corridors. This means domestic manufacturing facilities will have to re-invent their processes and supplier relationships to better centralize them and avoid the expenses and pollution incurred by shipping parts across the country.

As we transition to this new age, EV charging manufacturers are facing a plethora of challenges as well as unprecedented/exciting growth opportunities. From adhering to the “Buy America” procurement requirements to working out the logistics of a new supply chain, manufacturers have a lot to overcome, all while trying to keep up with the demand of a growing population of EV owners.

Building Out Domestic Manufacturing

Right now, the biggest hurdle facing domestic EV charger manufacturing is time. In order to tap into the federal funds made available by recent legislation, manufacturers must build up domestic capabilities and expertise in new areas, from sheet metal fabrication to PVC manufacturing, quickly.

With these challenges, it may seem daunting to make the transition to domestic manufacturing. However, Blink Charging, a leader in the EV charging industry for close to 14 years, has long been aware of these concerns and is taking steps to overcome them.

Driver with Blink EV charger app.

Managing the EV Charger Supply Chain

In June of 2022, Blink acquired SemaConnect, a leading provider of EV charging infrastructure solutions in North America with a state-of-the-art manufacturing facility in Maryland. This acquisition brought the complete design and manufacturing processes of Blink’s EV chargers in-house, allowing the company to comply with the “Buy America” provisions in federal law. The acquisition also marks Blink’s emergence as the only EV charging company to offer complete vertical integration – from research & development and manufacturing to EV charger ownership and operations – creating unparalleled opportunities for the company to control its supply chain and accelerate go-to-market speed while reducing operating costs.

In addition, Blink recently announced its commitment to establish a new manufacturing facility in the United States, which will further increase its charger production capacity. While the search for the facility’s location is still ongoing, the plant will offer 200,000 square feet of space with the latest technology to manufacture both DC Fast Charging (DCFC) and Level 2 Chargers.

With one facility already up and running and another on the way, Blink is leading the charge in domestic manufacturing of EV charging infrastructure in the U.S.

Harjinder Bhade is Chief Technology Officer at Blink Charging

Green Car Time Machine - archive articles from Green Car Journal.

As GM was taking a high-profile with its Impact electric vehicle prototype in the U.S., Nissan was showcasing the marque’s FEV (Future Electric Vehicle) that GCJ editors saw in Japan. Over the next several years, Nissan continued its electric vehicle development and showed its FEV-II, a less sexy but more practical electric vehicle prototype. As its program evolved, the FEV series was dropped in favor of other electric and hybrid electric vehicle studies. Still, the design of the initial FEV in particular resonates as we look back at early electric vehicle programs. This article is reprinted just as it originally ran in Green Car Journal’s December 1995 issue to share perspective on Nissan’s early electric vehicle development efforts.

Excerpted from December 1995 Issue: The Nissan FEV, which debuted at the Tokyo Motor Show in late 1991, was a milestone electric vehicle concept for this automaker. It showed considerable thought as to what an electric vehicle could and should be, from its stylish exterior and handsome interior to an innovative powertrain and quick-charge system that garnered substantial world-wide attention.

Side view of Nissan Future Electric Vehicle concept car.

FEV a Quick Charge Electric Vehicle

As they say, that was then, and this is now. Nissan has now provided a follow-though by introducing its latest electric vehicle iteration, the FEV-II. This model is a bit less sporty than the original but definitely appropriate for the coming electric vehicle market. Somewhat in the vein of Volkswagen's Beetle-like Concept1, the FEV-II is handsome, rounded, and sure to be popular on the auto show circuit, and maybe even the highway.

The four-passenger (2+2) coupe's design is the handiwork of Nissan Design International, located in Southern California. It features a flat floor so batteries can be secreted beneath without infringing upon passenger comfort or space – a nice touch.

Nissan is once again credited with offering advanced thinking in its electric vehicle concepts. The FEV-II uses the advanced lithium-ion batteries this automaker is developing in conjunction with Sony. Top speed of the 3120-pound car is said to be 75 mph, while single-charge driving range is a claimed 125 miles. The EV can be charged from any standard electrical outlet via a detachable charging system.

Nissan FEV II electric vehicle concept rear view.

FEV-II Uses Lithium-Ion Batteries

Nissan is among many automakers who are actively working to develop viable electric vehicles to meet the 1998 ZEV mandate in California and other states. While GCJ editors have not yet road tested Nissan's new FEV-II, behind-the-wheel time has been spent in the automaker's Avenir demonstration EV. Not surprisingly, GCJ testers found it to be quite a capable electric vehicle with good acceleration and handling, indicating a great deal of sophistication in Nissan's EV development program. This electric station wagon also exhibited a high level of comfort – surprising from an electrically retrofitted production vehicle.

The automaker has been field testing 15 Avenir electric vehicles with Kyushu Electric Power Company, a Japanese utility which helped develop the electric variant. The station wagon is reportedly capable of a 50 to 100 mile single charge driving range with a top speed of 70 mph.

Instrument display as you drive electric.

You know the drill. Get in the car, commute to work, run your usual errands, and at regular intervals stop at the gas station to fill up. It’s a routine that’s been ingrained in the driving psyche for decades. If you want to simplify, then consider a move from gas and instead drive electric. Driving an EV is not a panacea to life’s constant demands but all in all, it calls for less of your time and attention. Here are a few reasons why driving an electric vehicle may be for you.

EVs Can Enhance Convenience

How much is your time worth? Charging an EV’s battery can conveniently be done at home with a garage charger, through a growing public charging network, and increasingly at workplace chargers. Those regular trips to gas stations? Cross them off your list, forever. Another benefit that can save time – and frustration – is the ability for solo EV drivers to use high occupancy vehicle (HOV/carpool) lanes in some states, which can shave plenty of time off a commute.

It's Cheaper to Drive Electric

Electricity is a far cheaper way to fuel a car than gasoline. In fact, electric motors are so much more efficient than internal combustion engines, the most efficient electric vehicle today nets an EPA combined city/highway rating of 140 MPGe. The savings don't stop there. If you charge at home, additional savings can be realized by signing up for an electric utility’s favorable electric vehicle rate plan, then timing a charging session during a plan’s specified hours.

Less Maintenance Required

Vehicle maintenance is key to a healthy vehicle. Tune-ups keep a typical car running its best over the long haul, making the most efficient use of the gas it consumes and optimizing combustion so it produces fewer tailpipe emissions. One of the important benefits of an electric vehicle is that maintenance needs and costs are significantly diminished. Simply, there are far fewer moving parts in an EV than a conventional internal combustion vehicle, which means there’s less to take care of and fewer appointments needed for service.

Get a Subsidy to Drive Electric

Electric vehicles today are almost universally more expensive than those powered by traditional internal combustion engines. But if you want one, the federal government – along with many states, electric utilities, and other sources – can make it easier to buy an EV with generous subsidies of many thousands of dollars. The most valuable of these subsidies comes from the recently passed Inflation Reduction Act of 2022, which offers a potential clean vehicle tax credit up to $7,500 if you buy a new plug-in electric vehicle and up to $4,000 on a qualifying used EV.

Polestar 2 driving on highway.

Status Comes with the Territory

Driving an EV makes a statement. We’ve seen this over time as Toyota’s Prius hybrid made its way to U.S. highways just over 20 years ago and was embraced by environmentalists and celebrities. The instantly recognizable profile of the Prius was part of the attraction, which shouted, “Look, I care about the Earth!” To many, that was reason enough to drive a Prius. To a whole lot of others it was just kind of obnoxious. Thankfully, today’s expanding field of eco-friendly electric vehicles offer a different approach. Some feature futuristic design cues that push the envelope in a positive way, but most are so mainstream you have to look for EV badging. Either way, your immediate circle of influence will recognize that you’re driving an electric vehicle and that confers positive status.

Roger Caiazza, blogger, Pragmatic Environmentalist of New York.

Not so long ago, it was generally accepted that plug-in hybrid electric vehicles (PHEVs) and compressed natural gas (CNG) vehicles could be used as bridge technologies until ‘zero-emissions’ vehicles could perform like existing vehicles, at similar cost.  Unfortunately, politics in New York and elsewhere demand net-zero by 2050 with policies that preclude their use. 

I have spent a lot of time the last three years evaluating New York’s net-zero by 2050 target mandated by the Climate Leadership and Community Protection Act (Climate Act) from a pragmatic point of view. Pragmatic environmentalism is all about balancing the risks and benefits of both sides of issues. Most troubling in the quest for net zero is the lack of consideration for tradeoffs.

PHEV and CNG vehicles banned by Climate Act.

In New York the mandated technology is ‘zero-emissions,’ either battery electric or hydrogen fuel cells.  PHEV and CNG vehicles have direct emissions and so will be banned.  The Climate Act fossil fuel accounting requirements inflate the global warming effects as compared to all other jurisdictions and mandate that upstream and life-cycle emissions also be considered.  On the other hand, the life-cycle emissions and impacts of the ‘zero-emissions’ technologies are ignored.

The Climate Act’s net-zero by 2050 transition is extraordinarily ambitious. The Scoping Plan that outlines the framework to implement this transition projects that in order to meet the net-zero schedule, over 30 percent of all light-duty vehicles sold will either be battery-electric vehicles (BEVs) or hydrogen fuel cell vehicles (HFCVs) in 2025, and 100 percent by 2035. For medium- and heavy-duty truck sales, the Scoping Plan projects that at least 10 percent sold will either be BEVs or FCEVs in 2025, and 64 percent by 2035.

PHEVs a Logical Bridge Technology

It's wishful thinking to presume that large percentages of people will choose BEVs and HFCVs, forgoing the flexibility of a personal car that has much greater range in all seasons, can be refueled quickly on long trips, and does not require expensive charging equipment at home.  PHEV technology eliminates range anxiety, refueling, and home equipment concerns. It also reduces fuel use and air pollution emissions significantly and uses a smaller battery pack than a BEV, which reduces the environmental impacts of rare earth mineral supplies and disposal that the Climate Act ignores.

When all the physical, cost, and logistical issues associated with hydrogen use are considered, it will not play a major role in the future. BEV technology doesn’t appeal to a majority of car owners because of nuisance constraints, but the technology could work. The same cannot be said for battery electric heavy-duty vehicles since range, refueling, and charging infrastructure constraints are deal breakers that prevent heavy-duty trucks from meeting the 2050 net-zero target. 

Natural gas trucks are a bridge technology to zero emissions.

CNG Trucks a Viable Alternative

There are serious inhalable particulate air pollution issues associated with diesel truck emissions at freight terminals in New York City. The Scoping Plan claims that replacing these trucks with zero-emission alternatives provides significant benefits. However, the plan’s zero-emissions aspirations ignore technological tradeoffs and the reality that CNG heavy-duty trucks are a viable alternative that would markedly reduce inhalable particulate emissions.  The problem with CNG is not technology since we know it works, but a problem with the development of fueling infrastructure and vehicle fleet turnover. It is not pragmatic to insist that heavy-duty trucks use unproven battery electric technology over other alternatives that can markedly reduce the air quality issues. 

The use of PHEV and CNG vehicles for personal and freight transport offers the opportunity for significant air quality benefits, at a cheaper societal cost, with less impacts on personal choice, and sooner than the ‘zero-emissions’ alternatives. Failing to consider those benefits while insisting upon a riskier technological approach is not good social policy. Someday, there may be a better alternative, but in the meantime bridge technologies that provide most of the benefits are the more appropriate policy approach.

Roger Caiazza, a retired Certified Consulting Meteorologist who has worked in the air quality industry for over 40 years, is a blogger at Pragmatic Environmentalist of New York

Green Car Time Machine - archive articles from Green Car Journal.

The world’s automakers have long pursued diverse alternative fuel technologies for good reason. Simply, the future of transportation may well unfold in surprising ways. Among the many advanced fuels explored has been hydrogen, and in fact, even amid today’s focus on battery electric power there continues to be significant interest in this zero-carbon fuel. Here’s a look at the amazing developmental work that BMW was conducting on hydrogen vehicles 18 years ago, as documented in Green Car Journal at the time. We lend perspective on the BMW H2R hydrogen vehicle’s evolutionary importance by presenting this article just as it ran in Green Car Journal’s Winter 2004 issue.

Excerpted from Winter 2004 Issue: In the quest for environmental leadership, there’s often a delicate balancing act as designers strive to create cars that are environmentally positive, yet offer the features drivers most desire. Clearly, core values must remain in focus during the process to retain the values and identity that distinguish carmakers from their peers.

BMW H2R hydrogen race car in shop.

Hydrogen a Focus at BMW

This has been BMW’s mission over the past decade as it has pursued hydrogen cars and the performance to go with them. You can’t, after all, lay claim to the title “ultimate driving machine” if your zero-to-sixty times are glacial and you slog through corners, even if powered by clean-burning hydrogen.

For years, BMW has been refining the liquid hydrogen fueled sedans that it has placed in field trials on multiple continents, championing the use of hydrogen in conventional engines in lieu of the more popular fuel cell. These hydrogen vehicles have improved over the years, making the most of renewable hydrogen fuel in their internal combustion powerplants.

BMW H2R hydrogen car on race track.

Record Setting BMW H2R

Now, this automaker is putting its stamp on the hydrogen record book with adaptations of this hydrogen engine technology, fielding a land speed record car that has passed the 185 mph mark and claimed an additional eight records as well. Along the way it has achieved recognition by the Federation Internationale de l’Automobile as the fastest hydrogen car in the world.

A distinction achieved at the high-speed Miramas Proving Grounds in France, BMW’s 285 horsepower H2R hydrogen car was propelled to 100 km/h in about 6 seconds, setting records in the flying-start kilometer; standing-start ½ kilometer, kilometer, and 10 kilometers; flying-start mile; and standing start 1/8 mile, ¼ mile, mile, and 10 miles. The record car was piloted by BMW works drivers Alfred Hilger, Jörg Weidinger, and Günther Weber, who took turns at the wheel of the H2R during their record-breaking session.

Cutaway view of BMW H2R hydrogen race car.

Powered by a V-12 Hydrogen Engine

The sleek and imposing car was conceived, designed, and developed by the automaker’s subsidiary, BMW Forschung und Technik GmbH. Its carbon fiber exterior was designed by DesignworksUSA, the California-based strategic design consultancy owned by BMW Group. This is the same design house that worked on the BMW E1 and E2 electric car prototypes in the early 1990s.

This BMW is motivated by a 6.0-liter V-12 engine modified to run on hydrogen, a gasoline powerplant normally found in the automaker’s 760i model. Among the engine modifications is a fuel injection system adapted to handle hydrogen, which uses injection valves integrated into the intake manifolds. Special materials are also used for the combustion chambers. Liquid hydrogen is carried in a vacuum-insulated, double-wall tank that’s fitted next to the driver’s seat.

Front of hydrogen BMW H2R developmental car.

Is the H2R just a whimsical exercise? Nope, it’s part of a larger vision. In fact, BMW plans to launch a dual-fuel 7 Series that will run on hydrogen or gasoline, sometime during the production cycle of the present model, surely at a price far lower than that of a hydrogen fuel cell vehicle. Exercises like the H2R help pave the way.

Ron Cogan, Publisher of Green Car Journal

If we view the automobile’s history of environmental improvement in modern times  – say, from the 1990s to present day – there is an important perspective to be gained. It has never been just about electric vehicles. That’s simply where we’ve ended up at present due to an intriguing alignment of influences and agendas, from technology advances and environmental imperatives to gas prices and political will.

Over the years, auto manufacturers and their suppliers, technology companies, energy interests, and innovators of all stripes have been hard at work striving to define mobility’s future. Fuels in their crosshairs have included ethanol, methanol, hydrogen, natural gas, propane autogas, biofuels, synthetic fuels, and of course electricity. Lest we forget, cleaner-burning gasoline and diesel have been part of the evolution as well.

We Are Betting It All On Battery Electric Vehicles

As a nation, we have always approached this challenge with an open mind and a determination to explore what’s possible, and what makes sense. Rather than declaring a winner, for decades the approach has been to keep our options open as we define the best road ahead for environmental progress. Now, by government fiat and funding, battery electric cars have essentially been declared the winner.

This is troubling. As a die-hard auto enthusiast and auto writer my entire adult life – and a member/supporter of the Sierra Club for decades –  I have developed some strong and well-grounded perspectives on cars, their environmental impact,  and the future of mobility. My advocacy for electric cars is genuine and well-documented over the 30 years I have been publishing Green Car Journal, and before that through my writing as feature editor at Motor Trend. Honestly, it’s hard not to be a fan of EVs after a year of test driving GM’s EV1 and then spending many tens of thousands of miles behind the wheel of other battery electric cars over the years. Yet, I now sit back and wonder at the ways things seem to be unfolding.

Afeela concept is new addition to electric vehicles.

News Focus is Skewed Toward EVs

As expected, electric vehicles took a high profile at the increasingly important CES show in Las Vegas and this attention will certainly continue at upcoming auto shows. News of innovations, strategic alliances, and all-new electric models proliferate today, showing how dynamic this field has become and underscoring the nonstop media attention that EVs enjoy. But progress does not mean electric vehicles should be our singular focus.

There are significant risks with an all-in electric car strategy. Not the least of these is that by deemphasizing the importance of petroleum and the potential use of other alternative fuels in the near-term – crucial components in fueling the national fleet as we appear to be heading toward an electrified future – we risk the stability of our economy and our national security.

Gas station sign with high prices.

Gas Prices Influence EV Sales

Yes, sales of electric vehicles have surged in the midst of extraordinarily high gas prices and heightened concern about climate change. However, history shows us that gas prices spike, drop, and then remain at levels that find drivers once again becoming complacent. This predictable script should provide incentive to make smart moves like diversifying our energy sources as we build the necessary infrastructure for an increasingly electrified world, rather than bet it all on EVs. So many of the elements for the EV’s success remain unclear or continue to pose significant challenges.

If interest in electric vehicles is decoupled from high gas prices and surging because of the urgent need to mitigate carbon emissions, then we will see electric vehicle sales continue to rise, perhaps dramatically. But if increased interest and sales is largely tied to the high cost of gas, then a lot of regulators, environmental interests, and EV-leaning consumers  – plus of course automakers that have gone all-in with electrics – are set for a serious reckoning.

Plug-in hybrid electric vehicle plugged in to charger.

All Forms of Electrification Important

All this isn’t to diminish the importance of electric vehicles. Rather, it’s a call to be mindful of the challenges ahead and look at the bigger picture. We should encourage electric vehicles – whether powered exclusively by batteries, a combination of internal combustion and battery power, or perhaps hydrogen –  in every reasonable way possible. In particular, hybrids and plug-in hybrids must play an increasingly larger role in the years ahead. We have come a long way over the past 30 years, and we have a long road ahead in the effort to decarbonize transportation and mitigate its impact on climate change. We need to keep at it, aggressively, and we need to prepare.

Let’s just not make assumptions that all will go according to plan. California’s decision to ban the sale of gasoline cars by 2035, in particular, will certainly find unexpected obstacles on the way to that aspirational milestone. It happened before with California’s Zero Emission Vehicle mandate more than two decades ago, which failed to realize its goal of 10 percent electric vehicle sales by 2001. Beyond California, similar hurdles will exist in other ‘green’ states like Oregon, Washington, and Vermont that have now adopted California’s 2035 gasoline vehicle sales ban, along with other ‘green’ states that will surely follow California’s lead.

Man assembling battery for electric vehicles.

Many Challenges for Electric Vehicles

There’s a lot going right for electric vehicles today. But there’s also a wide array of continuing challenges that face EV proliferation.  These range from persistently expensive batteries, high vehicle prices, and sold out EV production runs to shortages of essential materials, a nascent nationwide charging infrastructure, and a national grid woefully unprepared to reliably charge tens of millions of electric cars. Then there’s the question of whether consumer EV purchases will continue to accelerate or weaken in tandem with lower gas prices.

It’s one thing to devise ambitious goals and quite another to make them law, especially when so many assumptions are in play. Given all this, is a wholesale shift to electric cars and a ban on the sale of gasoline vehicles even possible just a dozen years from now? As a long-time automotive analyst and  EV enthusiast, I have serious doubts.

Green Car Time Machine - archive articles from Green Car Journal.

One of the more interesting electric cars in the early 1990s was the German-designed BMW E1 and then the U.S.-designed E2, innovative yet mainstream looking vehicles that illustrated BMW electric vehicle aspirations. The E2 was slightly more compact than the futuristic-leaning BMW i3 ‘megacity’ electric car that was to come some 25 years later. It was 8 inches shorter, 6 inches narrower, and 5 inches lower than the i3, plus 700 pounds lighter. The E2’s ‘hot’ sodium-sulfur battery was projected to deliver a 161 mile driving range, about 8 miles farther than the i3. To enlighten readers on BMW’s early electric vehicle development efforts, we’re sharing the following article from the Green Car Journal archives as it originally appeared in the January 1992 issue.

Excerpted from January 1992 issue: BMW’s E1, an electric concept vehicle now undergoing road testing in Europe, has just been joined by a new U.S. variant. Introduced at the Greater Los Angeles Auto Show, BMW’s new E2 prototype appears mainstream enough to be a mid-‘90s model. Its appearance is somewhat reminiscent of both a downsized minivan and sedan, leaning toward the look of Mitsubishi’s new 1992 Expo and LRV, and the Mitsu-built Eagle Summit.

E2: A Coming BMW Electric Vehicle?

Is this the precursor of a production model? We asked Robert Mitchel, product information manager of BMW of North America. “It’s a concept car,” Mitchell shares, “although it is fairly close to what a production car could be. Rather than taking a current 3 Series and modifying it as we have in the past, we’ve built this solely with the intent of designing a car that would satisfy consumer needs and potential legislation.”

BMW E2 electric vehicle illustration.

Among the important consumer needs to be served is a handsome package, and the E2 does provide that. Lower ground effects panels, distinctive BMW grillework, and an aero exterior are distinct design features. While the initial E1 was designed in Germany by BMW Technik GmbH, the automaker turned to California-based Designworks/USA (which is 50 percent owned by BMW AG) for the U.S. version.

Designing the BMW E2

According to Designworks/USA president Chuck Pelly, the studio’s intent was to give the E2 a formidable stance, with strong wheel flares and tires moved outboard as much as possible. A more substantial hood and bumper system were also integrated. “It’s a totally new body,” adds Pelly, “that’s more traditionally BMW styled, with less reversals” than the original E1. It’s also longer, wider, and lower with a smoother overall shape.

Inside the E2 variant is seating for four with storage behind the rear seat. A rounded dash integrates driver and passenger side airbags and a speedometer, range indicator, and clock. Forward/reverse controls and an electric handbrake are also provided. Designworks/USA is currently working on a completely new and more luxurious interior for the E2.

Illustration of BMW E2 electric vehicle interior.

Efficient But Not BMW Quick

Both rear drive models use a new Unique Mobility [UQM Technologies] brushless DC motor mounted at the rear axle. The 45 hp, motor is efficient, offering very respectable power by EV standards. But the E2’s acceleration numbers point to fairly sedate performance when compared to internal combustion vehicles.

Bottom line: Could the E2 sell if it were produced as a mid-‘90s model? Green Car Journal editors believe so, with a few caveats. Acceleration is passable for an EV utilizing current state-of-the-art technology. But a projected 15.6 second 0-50 mpg (80 kph) time may not be acceptable to the mainstream BMW buyer who expects sporting performance from his driving machine – even if the E2 does exhibit a typically upscale BMW image.

BMW-style performance is possible by combining more potent electric propulsion with the E2’s advantageous curb weight. Perhaps integrating twin UQM motors would do the job (90 hp total), or using an advanced generation motor available closer to the time the E2 could make it to market. The LRV’s 1.8-liter engine supplies 113 hp total, 1 hp less than the GM Impact prototype’s twin electric motors … so electric propulsion can offer the level of highway performance driver’s have come to expect. It doesn’t seem such a stretch to conjure visions of contemporary BMW performance from an ideally configured E2.

Technical specifications for the E2 BMW electric vehicle..
2023 Green Truck of the Year logo.

The movement that’s bringing ever-greener vehicles to our highways is in hyperdrive today, with enormous focus, funding, engineering, and production devoted toward decarbonizing transportation at all levels. In today’s pickup field, this increasingly means the addition of batteries and electric motors to the powertrain in hybrid or full electric configurations.

Other approaches to increasing efficiencies and reducing carbon emissions are also being taken through more traditional methods, like improving combustion engines and transmissions, lightweighting a pickup’s body and frame, and improving aerodynamics and rolling resistance. Pickups employing these diverse strategies are all considered in the Green Truck of the Year™ program since there is no single pathway to greater environmental performance.

Illustration of a hybrid pickup.

What's Important to Truck Buyers

The pickup truck is a unique proposition in the ‘green’ car field. While its uses are pretty expansive – from highly functional personal use vehicles to high horsepower, ‘stump pulling’ workhorses – there are some givens when we talk pickups. We know this well because of the many years Green Car Journal writers and editors have spent working at pickup and off-road magazines in the past. Trucks must serve their core missions, seamlessly. Their job is to work hard, play hard, tow dependably, and haul what’s needed. They can serve as family vehicles these days with ease, so car-like comfort, connectivity, and style are paramount…even as they deliver the high functionality and improved environmental performance buyers demand.

Through the Green Truck of the Year™ program presented at the San Antonio Auto & Truck Show in Texas, it’s Green Car Journal’s mission to identify the pickup that best represents environmental performance while balancing the core needs of pickup buyers. Among the cornerstones of Green Truck of the Year™ analysis is weighing the merits of pickups integrating the latest efficiency technologies, balanced with cost, value, functionality, performance, and other factors. Also considered is a model’s availability to consumers, since the ability to actually buy and drive more environmentally positive models on our highways is as important as the ‘green’ technologies and capabilities they champion.

These are more complex issues today. We’ve seen order banks for some new or popular pickups like the Ford F-150 Lightning and Ford Maverick unexpectedly close for the model year, which means consumers are no longer able to buy one. Price is also an important consideration. While annual price increases for new models are a tradition in the automotive market, sudden and significant price spikes are not. Today’s reality is that materials costs and supply are wild cards in the auto industry, with silicon chips and especially materials for electric vehicle batteries major issues. How an auto manufacturer chooses to deal with this, such as Ford’s $12,000 increase in the entry level cost of its F-150 Lightning, has a direct impact on a vehicle’s affordability and availability to buyers. All this is taken into consideration in determining the Green Truck of the Year™.

Green Truck of the Year press conference.

Green Truck of the Year Finalists

Pickups that made the cut as finalists this year included the Ford F-150 Lightning, Ford Maverick, Hyundai Santa Cruz, RAM 1500, and Toyota Tundra. Each, in its own way, offers features and powertrains allowing pickup enthusiasts the opportunity to drive with greater efficiency and lower carbon emissions. Because of their commendable environmental achievements, these five finalists are recognized with Green Car Journal's 2023 Green Car Product of Excellence™ distinction.

Electric Ford F-150 Lightning pickup truck.

Ford F-150 Lightning

The Ford F-150 Lightning is a champion of electrification. Powered exclusively by lithium-ion batteries and electric motors, this finalist features zero-emission travel of 240 to 320 miles before requiring a charge, depending on battery pack. F-150 Lightning does this while carrying on the Ford F-150’s reputation for dependability, durability, and performance. In fact, the F-150 Lightning’s acceleration and performance is stellar. It can haul up to 2235 pounds and tow up to 10,000 pounds, though towing or hauling heavy loads can significantly decrease the driving range of this all-electric pickup. The Lightning starts at about $52,000, though Ford’s order bank for this model is now closed.

Ford Maverick hybrid pickup truck.

Ford Maverick

Ford’s Maverick also brings efficiencies and carbon reduction to the pickup market, but in a different way. Starting at just over $22,000, this more compact pickup offers a standard 2.5-liter hybrid powerplant that nets up to 42 miles per gallon in the city, or a more powerful 2-liter EcoBoost engine. Maverick speaks to those who want a pickup with a smaller physical footprint that still fulfills a pickup’s expected mission, which it does handily. Clever engineering means the Maverick’s four-and-a-half foot bed can still carry a 4 by 8 foot sheet of plywood, with its multi-position tailgate at its halfway position and the plywood resting on top of the pickup bed’s wheel wells. Like the F-150, the order bank for the Ford Maverick has closed.

Hyundai Santa Cruz exterior.

Hyundai Santa Cruz

The Hyundai Santa Cruz is another example of a downsized pickup with high efficiency. Described by its maker as a Sport Adventure Vehicle, the Santa Cruz features a functional pickup bed that’s just over 4 feet in length, with the bed offering hidden bed storage and a lockable tonneau cover. It’s powered by a 2.5 liter four-cylinder achieving up to 26 highway miles per gallon, or a more powerful turbocharged 2.5-liter four, and comes in front- or all-wheel-drive. It can tow up to 3500 pounds and has a payload rating of 1500 to 1750 pounds. Santa Cruz offers a starting price of $25,500.

RAM 1500 pickup truck in the woods.

RAM 1500

With an entry point of just over $37,000, the RAM 1500 is a stylish and highly functional pickup that fits a variety of needs, whether at the worksite or the campsite, trailer in tow. It’s offered in Quad Cab and Crew Cab choices, with two- and four-wheel drive, two pickup box lengths, and eight trim levels. Gas and hybrid power options offer 305 to 702 horsepower and include a 3.6-liter eTorque V-6, 5.7-liter eTorque HEMI V-8, and 6.2-liter supercharged V-8. This pickup’s efficient 3.0-liter EcoDiesel is a fuel economy champ at 33 highway mpg. RAM 1500 offers a dedicated work ethic with the ability to tow up to 12,750 pounds and carry payloads up to 2300 pounds.

Toyota Tundra pickup truck exterior.

Toyota Tundra

Introduced in its third generation last year, the Toyota Tundra offers rugged styling and a broad range of capabilities. It’s available with two efficient twin-turbocharged 3.5-liter engines, the 389 horsepower i-FORCE V-6 or a 437 horsepower i-FORCE MAX V-6 parallel hybrid. It can tow up to 12,000 pounds and carry payloads up to 1920 pounds, with a driving range that can reach 700 miles. Tundra offers a wide range of features, amenities, and advanced driver assist systems and is available in Double Cab or CrewMax choices with two- and four-wheel drive,

Kimerly Shults of Stellantis and Ron Cogan of Green Car Journal.
Kimberly Shults of Stellantis accepts 2023 Green Truck of the Year award from Green Car Journal publisher Ron Cogan.

RAM 1500: Green Truck of the Year

Green Car Journal’s 2023 Green Truck of the Year™ is the RAM 1500. This pickup presents an excellent choice for buyers seeking a stylish and hard-working truck that offers efficient hybrid engine choices, plus the ability to tow and haul loads within its substantial ratings, with no limitations.

RAM 1500 features handsome styling, loads of connectivity and driver assist features, and the kind of comfort and functionality appreciated by everyday drivers and those who use their hard-working pickups on the job. Performance is a given. The 3.6-liter eTorque-powered RAM 1500 delivers up to 26 highway mpg with a driving range approaching 600 miles, while the 3.0-liter EcoDiesel nets 33 highway mpg and a driving range of 1,000 miles. Highway driving is a joy and off-roading an adventure if you’re so inclined. Importantly, this pickup’s capabilities dependably meet all the needs of personal, work, and recreational use, confidently delivering the substantial hauling and worry-free towing capability so many truck buyers expect and demand.

Green Truck of the Year trophy on truck tailgate.

Green Car Time Machine - archive articles from Green Car Journal.

Everyone is familiar with Tesla these days. In its early years, though, Tesla was just another aspiring automaker with big dreams and enormous challenges, and at times, seemingly insurmountable financial hurdles. That’s all changed and Tesla is now viewed as a serious competitor by the world’s legacy automakers. Today there’s the Tesla Model 3, Model S, Model X, Model Y, and Tesla Semi. Coming up will be a second-generation Tesla Roadster and Tesla's highly-anticipated Cybertruck. Sixteen years ago, Green Car Journal featured the company’s original electric Roadster and shared the emergence of Tesla as a potential competitor in the electric vehicle field. We present this article just as it ran in Green Car Journal’s Fall 2006 issue to lend context to the ever-unfolding Tesla story.

Excerpted from Fall 2006 issue: Only giant corporations have the resources to develop competent, competitive automobiles, and only internal combustion-powered cars offer the performance and practicality required by today’s drivers. The team at Tesla Motors is tasked with turning these conventions onto their respective heads…and they’re doing it. 

Tesla Roadster cutaway illustration.

Lithium-Ion Battery Pack

From its founding in 2003, most of the company’s efforts have gone into developing the heart of the car, the Energy Storage System (ESS). Some 6,831 lithium-ion cells – each slightly larger than a typical AA battery – are contained inside a large enclosure that fits neatly behind the Roadster’s two seats. The batteries are liquid cooled and attached to an elaborate array of sensors and microprocessors that maintain charge balance between the cells. Tesla chose a commonly used lithium-ion cell so that battery development will continue to drive down the cost and improve performance.

Also developed internally is the motor, which features remarkably high output for its small size: 248 hp and 180 lbs-ft of torque. The motor acts as a generator whenever the driver lifts off the throttle, providing an ‘engine braking’ effect similar to conventional cars, while also recharging the batteries.

Tesla Roadster driving on highway.

Tesla Roadster has Lotus Influence

The Roadster’s chassis is based on that of the Lotus Elise sports car, but lengthened and beefed up to handle the Roadster’s roughly 350 pounds of extra weight, largely attributable to the battery pack. The body design was penned by the Lotus Design Studio, and final assembly is completed at the Lotus manufacturing facility in England.

Along with a top speed of 130 mph, the company claims a zero to 60 mph time of four seconds, on par with some of the world’s top supercars. But the real test for an electric car is range. Tesla says the batteries will last for 250 miles of pure highway driving, and can be recharged using Tesla’s home-based charging system in under four hours. The batteries are expected to last five years or 100,000 miles, after which time they’ll have 80 percent of their original capacity. In terms of real-world practicality, these are some of the most impressive numbers we’ve seen from an electric car.

Behind the wheel of the Tesla Roadster.

High Performance, High Price

There’s one more crucial number: price. The Tesla Roadster starts at $89,000 and tops out at $100,000. That’s steep, but not wholly unrealistic given the level of performance the car achieves.

Tesla Motors thinks there’s plenty of demand for their car, and early signs look good: the first 100 Roadsters were snapped up right away. It will be interesting to see if that kind of buying fervor continues as Tesla opens its direct sales and service centers, first in Northern and Southern California, followed by Chicago, New York, and Miami. The company begins the first production run of 600 to 800 cars next spring, maxing out at 2500 per year after three years if demand holds.

Tesla Roadster with blurred background.

Tesla Roadster an Ideal Launch Vehicle

Plans are already in the works for the next model, a 4-door sedan in the vein of Toyota’s Prius. Tesla’s Mike Harrigan thinks that in five to six years, the cost of batteries will have been cut in half – the Roadster’s pack costs about $25,000 today – and will be capable of providing a family sedan with a range of 500 miles, double that of the Roadster.

The Tesla Roadster may be the perfect weapon to launch the Tesla brand. It’s eye-catching and fast and targeted at a segment that can realistically command high prices, thereby helping to absorb the high cost of the batteries and high-tech control system. The next step, and perhaps the greater challenge, is to drive this high concept down to the mainstream. We’ll be watching intently.  

Rear view of Tesla Roadstery.
Greg Roche, Clean Energy Fuels.
Greg Roche, VP of Sustainability at Clean Energy.

Trucking companies, and the shippers that hire trucking companies, are making bold commitments to cut their carbon footprint – such as becoming net zero by 2030. Yet achieving net zero or better requires more than operational improvements. Alternative technologies are needed to move beyond even the cleanest diesel platform. Renewable natural gas (RNG) has emerged as the leading pathway for low carbon, clean air trucking. There are three compelling reasons why RNG is helping sustainable companies decarbonize their transportation today.

Lowest Carbon Transportation Fuel

RNG is derived from organic material found in green waste, food waste, landfills, sewage treatment, and livestock manure. These organic wastes naturally decompose into methane. Methane that leaked into the atmosphere is a potent short-lived climate pollutant and greenhouse gas. Rather than releasing into the atmosphere, methane can be captured and converted into a drop-in replacement fuel for conventional natural gas.

When used for vehicle fueling, RNG reduces carbon by capturing methane that would escape into the atmosphere; and by replacing high-carbon diesel fuel. The chart below shows the carbon intensity of traditional fossil fuels and low-carbon alternative fuels. RNG produced from dairy manure has carbon emissions that are up to 300 percent cleaner than diesel fuel, and has the potential to be negative carbon intensive. Replacing just 25 percent of a fleet’s diesel trucks with negative carbon intensive RNG from dairy manure can reduce a fleet’s carbon emissions by 100 percent.

RNG is lowest carbon alternative fuel.

RNG Trucks Improve the Air

Many areas of the U.S. have harmful air, and diesel trucks play an oversized role in local air pollution. The greater Southern California area, California’s Central Valley, Houston, Dallas, Salt Lake City, and other metro areas share this air pollution problem. Air pollution contributes to respiratory, cardio, and other illnesses. Studies have linked local air pollution to susceptibility to COVID-19, Alzheimer’s disease, and cancer. Diesel trucks emit high amounts of local air pollutants such as oxides of nitrogen (NOx) and diesel particulate matter. Diesel particulate matter is classified as a toxic air contaminant and is composed of carcinogenic compounds.

Trucks powered by RNG have 90 percent lower NOx emissions than a new diesel truck and over 98 percent lower NOx emissions than many of the diesel trucks in use today. RNG-powered trucks have zero emissions when it comes to carcinogenic diesel particulate matter.

RNG Trucks Save Money

RNG fuel costs less than diesel fuel. Fuel savings are particularly amplified today with skyrocketing diesel prices. RNG prices are also less volatile than petroleum fuel.

RNG trucks have great economics compared to other emerging clean technologies. The cost of these emerging technologies is 200 percent to 300 percent more expensive than RNG trucks. These emerging technologies have far more expensive charging or fueling infrastructure costs than RNG fueling. An RNG truck at one-half to one-third the cost of other technologies has better carbon reduction and equivalent air quality benefits.

Leaders are Taking Action Today

Climate pollution and air pollution are problems that exist today, not far in the future. While it is noteworthy for companies to make aspirational goals to achieve net zero carbon emissions in the future, RNG trucks offer the ability to achieve net zero immediately. RNG truck technology has been proven and perfected over the past 14 years. RNG engines are mass produced by Cummins, and RNG trucks are mass produced by Freightliner, Peterbilt, Kenworth, Volvo, and Mack. RNG fueling infrastructure is available throughout North America and is rapidly expanding. Clean Energy alone has over 560 fueling locations at customer sites and at retail locations.

Companies like Amazon, UPS, Waste Management, SAIA, Estes, and TTSI are deploying thousands of RNG trucks today. What do these sustainability-leading companies know? RNG is the lowest carbon fuel available and offers an affordable alternative to diesel today that is proven and scalable.

Greg Roche is the Vice President of Sustainability at Clean Energy, the country’s largest provider of the cleanest fuel for the transportation market.

Tim Reeser, CEO of Lightning eMotors electric vehicles.
Tim Reeser, CEO of Lightning eMotors.

It’s been more than 100 years since Henry Ford’s Model T revolutionized the way the world moves people and goods. Ford didn’t invent the car, but over the course of about 30 years, he transformed the way vehicles are manufactured – increasing volumes, driving down costs, and converting them from expensive novelties to affordable conveyances for workers and families. Just as importantly, over the last 100 years, other entrepreneurs and innovators developed an infrastructure ecosystem to ensure these vehicles could be fueled, serviced, and customized.

More than a century later, we find ourselves on a new transportation frontier that is once again transforming the way society moves people and goods. This time we are transforming how vehicles are propelled, from internal combustion engines (ICE) to electric, and modernizing the fueling infrastructure. Gone will be the days of imported crude, cumbersome fluid tanker trucks, and lines at the gas station, in favor of producing fuel via localized grids and microgrids, and distributing that fuel via depot chargers, home chargers, and public charging stations.

As we approach 30 years since the first modern retail offering of battery-powered electric vehicles, it’s clear that EVs – of all shapes, sizes, models, and payloads – are here to stay. I am certain of this because nearly every day I witness the reaction of drivers when they operate a Lightning eMotors commercial EV for the first time – smooth, quiet, powerful, and equipped with safety features never before available on commercial vehicles. I see their response when we talk about efficiency of nearly 60 MPGe on the exact same vehicle that got 13 mpg as a gasoline vehicle.

These products and this industry are my passion. I have dedicated myself to creating a company that not only builds amazing products, but also builds products that make both environmental and business sense, a company that helps move the planet in the right direction. As CEO of Lightning eMotors (NYSE:ZEV), a leading manufacturer of commercial vehicle electrification, telematics, and energy and charging solutions, I have seen that it is possible to build exciting products that also have a compelling business case and are environmentally transformational.

Industry and Government Aligned

Not only has growing public awareness of the environmental and health benefits of electric vehicles led to government legislation and funding to promote the transition from internal combustion engines to electric, but evidence for the EV business case continues to grow as well. Companies of all sizes and purposes are dedicating resources to support the transformation of their fleets to electric vehicles.

In addition to the growing list of companies that has pledged a commitment to reducing their fleet impact on the environment, within just the past year the Environmental Protection Agency allocated $5 billion to replace existing school buses with zero-emission and low-emission models through the Clean School Bus Program. In addition, the Federal Transit Administration announced almost $5 billion for public transit agencies, states, and Tribal governments to support public transportation across the country through its Low or No Vehicle Emissions Program; and the United States passed the $1.2 trillion Infrastructure and Jobs Act and the Inflation Reduction Act, both of which provide billions in new funding for EVs and EV infrastructure. History has rarely seen industry and government so closely aligned on a path forward. This is yet another sign that electric vehicles are the future.

Plugging in Lightning eMotors electric vehicles.

Specialty Commercial Vehicles

While it’s true, for the time being, that up-front costs are higher than their petroleum-powered counterparts, as industry continues to invest in EV technologies and as government continues to provide incentives to purchase, more electric vehicles are being manufactured. Scale is growing and costs are coming down. What’s more, data is proving that over their lifetimes, electric vehicles will last longer and require far lower maintenance and fuel costs.

Critics point to the bumps in the road for EV makers as proof that the endeavor itself cannot succeed. Of course, establishing a successful EV industry comes with challenges. But we are at the point where EVs have proven themselves to make sense logistically, financially, and environmentally, and transitioning from internal combustion engines to electric is both financially prudent and impactful for the environment.

A little-talked-about factor helping to lower the cost of entry is the increasing production of specialty commercial vehicles. In fact, according to the 2022 IEA Global Electric Vehicle Outlook, the business case for light commercial vehicles (LCV) is stronger than for cars, with sales of LCVs increasing 70 percent in 2021.

Passenger vans are among Lightning eMotors' electric vehicles.

EVs in Commercial Fleets

Those of us who spent more time at home during the pandemic, marveling at how easy and ubiquitous home delivery has become, are probably not surprised by that. And it’s only increasing. In a post-COVID world, e-commerce sales are forecast to rise 37 percent from 2020 to 2024, according to Statista Digital Market Outlook 2020.

We estimate there to be 2,500 electric vehicles in use in commercial fleets across North America – many as transit buses and cargo delivery vans and trucks, but also as passenger vans, shuttle buses, school buses, ambulances, and motor coaches. And the number is growing every day, as business and industry recognize the value of zero-emission transportation options for customer satisfaction, growing investor demands for sustainability and, importantly, their bottom lines.

Adoption no longer depends on emotion. Choosing EVs for commercial use is a demonstrably smart business decision. It’s no longer a matter of if the world’s primary source of transportation will be EVs but when…and when is now.

Lightning eMotors electric RV.

Electric Vehicles are More Efficient

At Lightning eMotors, we see firsthand through our advanced telematics capabilities the efficiency of all our zero-emission vans, trucks, and buses through every phase of their lifecycles. Our vehicles have demonstrated between four-and-six-times better efficiency than their gasoline-powered siblings over the last 2.3 million real-world miles. In total, vehicles deployed by Lightning have removed more than 1,850 tons of CO2 from our environment.

As pathways toward adoption continue to grow, some companies will succeed, some will consolidate, and a few will fold. Regardless, the commercial EV market is now firmly established and will continue to make a positive impact on air quality, greenhouse gas emissions, and its customers’ bottom lines.

Henry Ford is quoted as having said: “Don’t find fault, find a remedy.”

The commercial EV industry is a remedy. It’s a remedy for business costs, efficient and effective resource use, and reducing carbon emissions into the environment, and it has been quietly making inroads into the mainstream for the past three decades.

Before long, the days of internal combustion engines dominating our roadways will be as much a symbol of the past as Ford’s Model T.

Tim Reeser is CEO and Founder of Loveland, Colorado-based Lightning eMotors

Toyota bZ4X electric car.

Behind the wheel of Toyota’s new bZ4X electric vehicle, I’m given to a bit of reflection as to why this car has come to be. After all, Toyota is a specialist in hybrid vehicles and is noted for its focus and leadership here, not battery electric cars. But these days Toyota is feeling the pressure – actually, lots of it – to bring all-electric vehicles to a wanting market.

In between Toyota’s hybrid offerings and its emerging focus on electric vehicles are the  automaker’s plug-in hybrids that blend characteristics of the two. The Toyota brand has a pair of these now – the RAV4 Prime offering 42 miles of electric driving and 640 miles total range, and the Prius Prime offering 25 miles on battery power with a total driving range of 600 miles. We expect other models to join in soon enough.

A Timely EV Introduction

So why the bZ4X battery electric vehicle? Because it’s time, and also because it’s a critical link to Toyota’s ‘Beyond Zero’ (bZ) future and an array of battery electric, plug-in hybrid, and hybrid Toyota models in the pipeline. The automaker is serious about this. To support its growing electrification effort, Toyota has announced massive investments in battery manufacturing for its electrified vehicles, including $3.8 billion alone for a new battery manufacturing facility in North Carolina.

Toyota has made some earlier forays into the electric vehicle field in the States, but it’s been a while. The automaker fielded its first RAV4 EVs here from 1997 to 2003 in response to California’s zero emission vehicle mandate, and then a newer generation RAV4 EV from 2012-2014, developed with Tesla. It’s been hybrids and plug-in hybrids ever since, plus of course the Toyota Mirai hydrogen fuel cell electric vehicle, though most don’t view that model as a battery electric vehicle competitor at this time.

Toyota bZ4X electric vehicle and night skyline.

Toyota bZ4X Design

Segue eight years ahead from Toyota’s last battery electric vehicle experience and here we are with the bZ4X. It’s been worth the wait. What we have in the bz4X is a stylishly modern intro to Toyota’s coming line of battery electric vehicles, sized similarly to a RAV4 but just a bit longer and lower. Its body design features disparate elements like a distinctly flat ‘hammerhead’ front fascia combined with sharp angles, pronounced fenders, sculpted sides, and a flowing roofline. All come together nicely as an appealing whole…a design not too conservative, and not leaning too far into the future.

Low-profile headlamps are accented by a dark contrast band that flows from the front fenders and across the front end. Matching contrasts are found at the rear fenders as well, with black accented rocker panels running from well to well. At the rear, the bZ4X innovates with a pair of aerodynamic roof extensions at either side of the upper hatch, lending the impression of a future-esque roofline spoiler. The bottom of the glass features a slight lip-of-a-spoiler with a thin fender-to-fender running light below, along with distinctive angular taillamps.

Toyota bZ4X cabin.

Familiar Cabin, With a Twist

Inside is a comfortable and modern interior featuring all the necessary elements for a satisfying driving experience, leaning a bit towards the spartan side. While much is familiar to the breed, there are design elements that align with the forward-thinking theme embodied by the car’s distinctive exterior. In particular, we’re thinking of the dashboard and instrument panel design ahead of the driver, which features an unusually long expanse between the steering wheel and MMI information display. Additional information and multimedia features are presented in a 12-inch widescreen display in the center dash position. Driver and passenger seats are comfortably bolstered for support and plenty of room is provided both front and rear, with rear legroom what one would expect in this size of vehicle. A panoramic roof is optional.

The bZ4X is well-equipped with the advanced driver assist features expected in today’s new models. It features the first use of Toyota’s latest TSS 3.0 Safety Sense suite, which includes advancements like improved pre-collision with guardrail, daytime motorcyclist, and low-light cyclist detection, and enhanced lane recognition. Other tech features include cloud-based navigation offering real-time traffic information and parking space availability, over-the-air software updates, and a digital key feature enabling drivers to lock, unlock, and start their bZ4X with their smartphone.

Rear seats in Toyota bZ4X electric car.

Single or Dual Motor Models

Drivers can choose single- or two-motor bZ4X variants. The former achieves an EPA estimated 119 combined MPGe with a 252 mile driving range, and the latter a combined 104 MPGe with a 228 mile range. Output for the single front-wheel drive model is 201 horsepower with the two-motor AWD version adding just 13 additional horsepower to the total. Energy is supplied by 71.4 and 72.8 kWh lithium-ion batteries, respectively. Both versions deliver a fun driving experience with confident ride and handling, quick torque at the ready, and plenty of power for anyone’s every day driving needs. With the dual-motor version delivering a 0-60 mph romp in the mid-seven second range, acceleration is brisk but does not approach the performance realm of some electric vehicles.

Toyota’s bZ4X is clearly an important introduction for this automaker that reinforces its continuing journey towards electrification. However, it does not mean that Toyota is convinced battery-powered vehicles are a proper all-inclusive strategy. The world’s largest automaker has been clear that it is not ‘all in’ with electric cars in the same way as some of its high-profile competitors, and the company has caught a lot of heat because of this. Rather, Toyota’s well-reasoned take is that multiple approaches exist to solving the interconnected issues of personal transportation and environmental sustainability.

A Balance of Electric Offerings

Electrification is a big part of this. It’s just that Toyota’s strategy does not embrace a tunnel-vision approach in which all roads lead to a plug, or a model without a gas cap. Some take form as hybrid, plug-in hybrid, hydrogen fuel cell, and yes, even battery electric vehicles. There is a balance here because one is needed since not everyone’s needs are the same.

An earlier Green Car Journal perspective shared by Toyota’s chief scientist, Dr. Gill Pratt, adds food for thought. Considering the finite resources available for worldwide battery cell production, and the carbon emitted in their production, charging, and use over time, it’s important they are used in the best way possible. Optimum use achieves a higher carbon return on investment (CROA) as cells are used closer to their full potential. EVs with large battery packs regularly making use of their range potential make sense and offer a higher return.

Toyota bZ4X charge port.

Best Use of Battery Cells

In Dr. Pratt’s illustrations, however, a fully electric vehicle with hundreds of miles of range primarily driving a short daily commute offers a poor return, since the majority of the cells are unneeded most of the time and are simply carried along as dead weight. Using this same number of cells in numerous plug-in hybrid models requiring smaller battery packs would offer a much more favorable carbon return, if these PHEVs are driven in ways that make best use of their more limited battery electric range.

This isn’t to say that plug-in hybrids are an inherently better choice than electric vehicles, or the other way around. It just means that needs vary, and pairing needs with an electrified vehicle’s capabilities makes the most environmental sense.

With hybrids and plug-in hybrids covered in the Toyota lineup, the missing link – the all-electric bZ4X – is now here to fill the need. Those seeking a crossover SUV offering expected zero-emission driving range, eye-catching style, and a comfortable and confident driving experience should look into Toyota’s new electric crossover. At a base price of $42,000, it provides what the brand promises – quality, thoughtful design, and user-friendliness, and no doubt the satisfying ownership experience the Toyota brand is known to deliver. Plus, of course, zero emission driving every mile you travel.

Green Car Time Machine - archive articles from Green Car Journal.

Toyota’s path to producing all-electric vehicles has been a long one, highlighted by the RAV4 EV model it fielded to fleets in response to the California Air Resources Board’s Zero Emission Mandate in the 1990s. Green Car Journal editors test drove variations of this small electric SUV during those early years of the modern electric vehicle’s development. We were impressed by Toyota’s exploration of the potential market for battery EVs at the time. To lend perspective on this automaker’s electric vehicle development, we present this article on the Toyota RAV4 EV pulled from our archives, just as it ran in our January 2002 issue.

Excerpted from January 2002 issue: Many thought the RAV4 EV – the electrically motivated compact sport utility vehicle from Toyota – was gone, the victim of a completed agreement with the State of California in the late 1990s. But it’s not. Toyota Motor Sales USA is bringing the sporty little EV back, this time making it available to retail customers in California, not just fleets. Sales are slated to begin in February 2002.

Rear view of Toyota RAV4 EV.

Fleet Service First

RAV4 EVs made their mark during the late-1990s as hundreds of these were leased and placed in fleet service. Some 700 of the 900 RAV4 EVs were in use in California. That occurred because of requirements imposed on automakers, including Toyota, by the California Air Resources Board, the result of the Memoranda of Agreement that accompanied postponement of the 1998 Zero Emission Vehicle Mandate.

That was then, this is now. No mandate exists this year, although all automakers are feeling the pressure of the impending 2003 ZEV rule that will require major automakers to sell large numbers of EVs to meet a 2 percent threshold. In retrospect, maybe Toyota’s move to bring the RAV4 EV back isn’t surprising after all.

RAV4 EV Powertrain

The RAV4 EV is powered by a maintenance-free, permanent magnet motor that produces 67 horsepower (50kW) and 140 lb.-ft. torque, providing an electronically governed top speed of 79 mph. Front wheel drive is via a single speed transaxle, with reverse provided by backward motor rotation.

A sealed, 288 volt nickel-metal-hydride (NiMH) battery pack provides energy to the motor. This pack, comprised of 24 12-volt modules, is located beneath the SUV’s floor to minimize intrusion into the passenger compartment and optimize the vehicle’s center of gravity. Charging this pack requires five to six hours.

Driving the Toyota RAV4 EV

Stopping power is supplied by an anti-lock and regenerative braking system that utilizes solid aluminum front discs and steel rear drums. The regenerative system returns energy to the batteries whenever the RAV4 EV is coasting or braking.

Time spent behind the wheel of the RAV4 EV has shown this vehicle to be fun, dependable, and capable of fulfilling most daily missions with ease, so long as they fit within the vehicle’s range capabilities. Since an electric motor produces peak torque immediately, the RAV4 EV offers good off-the-line acceleration but a rather modest 0-60 mph elapsed time of about 18 seconds. Driving range is between 80 to 100 miles per charge.

Efficient Heat Pump HVAC

Seating for five and ample space for cargo is provided in this five-door compact SUV. The interior offers the high level of function and comfort expected of a Toyota product, featuring such standard amenities as split fold-down rear seats, heated driver and front-passenger seats, adjustable-height front seatbelt anchors, and dual front airbags. Convenience is well accommodated by a heated windshield, rear-window wiper and defogger, and power door mirrors, windows, and door locks. An AM/FM stereo system with CD provides the needed tunes. Rear seat heaters and traction control are available options for cold climate use.

One of the advantages of electric vehicles is their use of heat-pump type air conditioning, an innovation that allows climate control functions to operate while a vehicle is turned off and parked. RAV4 EV drivers have the ability to set a timer and adjust their vehicle’s pre-heat or pre-cool function so the SUV’s interior is at a desired comfort level regardless of outside temperatures.

RAV4 EV Priced at $42,000

Toyota says the RAV4 EV will have a rather lofty suggested retail price of $42,000, although a $9,000 California Air Resources Board incentive and $3,000 federal tax credit brings the price of entry down to $30,000. This includes an in-home charger. Three introductory lease options will be offered that also include the use of the charger.

Every major metro market in California will soon find a participating RAV4 EV dealer. While initial sales are aimed exclusively in California due to Toyota’s need to address this state’s 2003 ZEV mandate, success here would certainly find the RAV4 EV making its way to other markets soon enough, starting with those poised to follow California’s lead by adopting the state’s ZEV requirements.

Toyota aims to make it easy for buyers to connect with their new electric vehicle. Like the Prius gas/electric hybrid, customers will have the ability to order the RAV4 EV online and take delivery through a participating dealer, as is the case with the Prius currently.