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.
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.
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.
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.
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
The electric revolution is upon us, the Infrastructure is not.
With the recent signing of the Glasgow Declaration on Zero Emission Cars and Vans at the 2021 United Nations Climate Change Conference, multiple automakers and 33 countries are now officially working toward the goal of making all new cars and vans sold globally zero emission by 2040. ‘Zero emission’ in this case is defined as producing zero greenhouse gas emissions at the tailpipe, as accomplished by electric vehicles, for example.
While much has been reported about the ever-increasing number of EV offerings and the growing interest and demand, there are still major hurdles to mainstream adoption. One of the most pressing is the dire lack of charging infrastructure.
Today, there are less than 2 million EVs in operation within the United States, according to some estimates, and fewer than 100,000 charging stations to service them — nearly a third of them in California. With projections for EVs in operation within the U.S. exceeding 25 million by 2030, the calculus on what it will take to keep those zero-emission vehicles running is staggering: Approximately 13 million EV stations need to be installed by 2030, which equates to 120,000 a month in the United States alone.
The trillion-dollar infrastructure bill just signed into U.S. law does include $7.5 billion earmarked for building out EV charging networks. But given the anticipated growth rate of EVs versus today’s infrastructure, it’s going to take a lot more than that. This is where companies like Charge Enterprises come in.
From on-the-go power banks to micro-mobility and EV charging stations, we design and engineer, select and source equipment, install, and coordinate software selection and if the customer requires, implement remote maintenance and monitoring services. So whether it’s a ChargePoint system or a Blink system, or a third-party charging company, what we do is the infrastructure build-out and ecosystem planning of the site location. Servicing and educating the client is critical in establishing a reliable, safe, scalable and flexible site for future demands.
We are equipment- and software-agnostic, which means that we can provide custom solutions with careful consideration of various business use cases to ensure efficient, effective, design plans that not only satisfy current needs but also account for future scalability, growth, and ever-advancing technology. Our experienced team with nationwide scale offers turnkey engineering, design, equipment and software specifications, planning, sourcing, and installation for EV charging ecosystems.
As important as EV infrastructure is, true global sustainability isn’t confined to how we fuel our mobility. That’s why our recent strategic alliance with the National Community Renaissance, one of the nation’s largest nonprofit developers of LEED certified affordable housing, is such a critical compliment to Charge’s infrastructure solutions for intelligent wireless campuses. This partnership will further align with National CORE’s dedication to providing high-performance affordable housing that integrates energy and sustainability to reduce harmful emissions, making all communities more sustainable, healthy and equitable places to live, work, and play – especially historically disadvantaged communities.
The demand for clean, sustainable charging infrastructure is building, whether for commercial properties, fleet depots, truck/van centers, retail facilities, auto dealerships, government, or residential. Our strategy is to make it simple for everyone to switch to an EV and other electrified technology. We’re helping accelerate the transition away from fossil fuels toward a fully electric future.
Andrew Fox is Founder, CEO, and Chairman of Charge Enterprises, a portfolio of global businesses specializing in communications and electric-vehicle charging infrastructure.
It’s well understood that driving electric is more efficient with a lower cost-per-mile than driving internal combustion vehicles. That’s especially true if you're charging an EV up at home. But what if you need to use public chargers on the road or live in an apartment where a commercial pay-per-use charger is your only option?
The cost can vary significantly since commercial chargers use different methods of payment. For example, many providers charge for the time it takes to charge a battery rather than the kWh of electricity delivered. This would be like gasoline stations charging for the length of time a nozzle dispenses gas in the fuel tank, not by the number of gallons of gas pumped. A few providers charge a per-session fee or require a monthly or annual charging subscription. While many public chargers at businesses and parking lots remain free of cost to EV drivers, that is changing over time.
When you pay by the minute, charging cost is influenced by an EV battery’s state of charge, ambient temperature, and the size of the EV’s on board charger. Different size chargers can mean a big difference in the cost of a charge even though the same number of kW hours are delivered. For example, earlier Nissan LEAFs had a 3.6 kW (3.3 kW actual output) on board charger while later ones had an updated 6.6 kW (6.0 kW output) version. Thus, it takes almost twice as long to charge an earlier LEAF at double the expense than later ones, even though both have the same 30 kWh battery. Many EVs now come standard with a 6.6 or 7.2 kW charger. When considering buying or leasing an electric model, keep in mind that a more powerful on-board charger means quicker and potentially more cost-efficient charging.
It’s an interesting bit of science that while charging an electric vehicle, the rate of charge isn’t linear but rather decreases as a battery approaches full capacity. If an EV has a lower state of charge (SOC) at the beginning of a charging session, charging occurs at its maximum rate, such as 3.3 kW, 6.6 kW, 7.2 kW, and so on. As the battery approaches 100 percent SOC, charging can slow to a trickle. The last 20 percent of charge can sometimes take as long as the initial 80 percent. To be most cost efficient, it’s recommended to only charge to 80 percent full capacity when using a public charger, especially one that includes time-based pricing.
For a charging cost comparison, let’s look at charging an EV with a 40 kWh/100 mile rating and a 50 kW on board charger. At a Level 3 charging station it would take about 48 minutes to get an additional 100 miles of range and cost between $6.24 to $16.80, depending where you did the charging. With a 350 kW fast charger this would take about 7 minutes and cost between $1.82-$6.93 to add 100 miles. This compares to $10.00-$13.33 for a gasoline vehicle that gets 30 mpg and fuels up at $3.00 to $4.00 per gallon. This shows the need for fast charging when away from home and charging with time of use chargers, and more importantly, the need for pricing solely on a per kWh basis.
While kWh charging is fairer to the consumer, some companies prefer time-based charging because the longer customers are connected, the more profit is made. However, public charging could be moving from time-to-charge to the kWh charge model. This will put the energy cost of EV operation in line with that of gasoline vehicles where fueling cost is determined by the cost of a gallon of gasoline, not the time it takes to refuel. Clearly, this change is needed.
New rules in California will eventually ban public charging operators from billing by the minute and require the fairer billing by kWh. The ban will apply to new Level 2 chargers beginning in 2021, and to new DC fast chargers beginning in 2023. Chargers installed before 2021 can continue time-based billing until 2031 for Level 2 chargers or 2033 for DC fast chargers.
The new rules do not prohibit operators from charging overtime, connection, or parking fees, or fees for staying connected after reaching 100 percent SOC, providing they are disclosed. Electrify America already charges 40 cents per minute if your vehicle is not moved within the 10 minute grace period after your charging session is complete. It remains to be seen whether more states will follow California’s lead. Laws will have to be changed in about 20 states where only regulated utilities can presently sell electricity by the kWh.
Charging providers like Tesla and Brink presently charge by the kWh in states where it’s allowed. For example, Tesla charges $0.28 per kWh while Blink charges $0.39 to 0.79 per kWh, depending on location and user status. California regulations require Tesla and others to show the price per kWh and a running total of the energy delivered, just like a gas pump.
Other charging considerations can affect the actual long-term cost of operating an EV. These include lower charge pricing and discounts that come with subscriptions, free charging incentives that accompany a vehicle purchase (like the first 1000 kWh provided free or 100 kWh of free charging per month), or if a charger is shared with another user. For Teslas, free unlimited Supercharger access has often come with the purchase or lease of a new Tesla model.
While EV technology is now relatively mature, pricing electric vehicle use is evolving. Hopefully, competition and a bit of government regulation should ultimately make it as understandable as it is now for gasoline vehicles.