Thatcham Research launches EV Blueprint to reduce write-offs

Safety and crash testing specialist Thatcham Research has launched a new strategy to try to cut the number of electric vehicles being written off by insurers.

The EV Blueprint sets out eight points for car makers, insurers and repairers designed to lower insurance costs through cheaper repairs and fewer “total losses”.

Thatcham Research argues that a growing number of EVs are written off unnecessarily every year because of problems around repairability.

Many of the problems stem from concerns around batteries, which account for up to 40% of a car’s value and can be difficult to safely assess and repair. The research body said that this meant even minor collision damage currently leads to many vehicles being prematurely declared a total loss and written off.

A recent survey by Thatcham and the Centre for Economics and Business Research (CEBR), found that battery-related issues remained the primary concern for 44.6% of insurers and 41.7% of repair professionals.

Thatcham says its framework sets out the steps needed to make EV batteries cheaper and easier to repair or replace, helping to keep more cars on the road and out of the scrapyard.

Eight steps to improvement

The EV Blueprint sets out eight recommendations – from making diagnostic systems and tools widely accessible to ensuring batteries and supporting components can be easily removed and replaced.

Dan Harrowell, principal engineer of advanced technologies at Thatcham Research, commented: “How affordable it is to insure these cars largely relies on how well the industry can handle repairs after accidents. As repair shops have become more experienced with electric vehicle technology, the costs of fixing these cars have already decreased by 10.7%.

“To continue making insurance more affordable as more electric vehicles hit the roads, car manufacturers, insurance companies and repairers need to keep collaborating to overcome any remaining challenges.”

Other key points of the blueprint include better battery protection against damage; modular construction that allows for elements such as brackets and casing to be replaced rather than the entire battery pack; and even using fixings instead of adhesives to make removal and repair easier.

It also suggests resettable safety loops that allow emergency services to cut off high-voltage systems without causing permanent damage to the battery, and moving components such as charging ports to less vulnerable locations.

Jonathan Hewett, Thatcham Research’s CEO, said: “We’re seeing too many repairable vehicles written off simply because current designs don’t accommodate efficient assessment and repair processes.

“Our Electric Vehicle Blueprint is the result of carrying out real-world EV impact assessments and repair procedures, in-house for more than a decade. These are practical, evidence-based recommendations to overcome three-year-old EVs being written off unnecessarily because of minor battery casing damage. This impacts consumer confidence and, fundamentally, undermines the sustainability credentials that make electrification so important in the first place.

“The eight recommendations we’ve outlined are entirely achievable. We already see these principles working in conventional vehicles – resettable safety systems, accessible diagnostics, serviceable components. There’s no technical reason why EVs can’t meet the same standards.”

More sustainable future

With EV batteries proved to have longer lifespans than initially expected, Thatcham said that better repairability would not just help cut costs but also deliver a more sustainable industry.

“This represents an achievable future state,” noted Harrowell. “The vehicle returns to service promptly, the customer retains their vehicle, salvage values improve and environmental impact is substantially reduced compared to manufacturing a new battery.

“Real-world data is showing that batteries can have a very long usable life that we should try to maximise through sustainable repair.”