Thatcham Research has launched a new strategy to reduce the number of electric vehicles being written off by insurers after accidents. The safety and crash testing specialist says too many repairable EVs are being scrapped unnecessarily.
The EV Blueprint outlines eight recommendations for automakers, insurers and repair shops. The goal is to lower insurance costs through cheaper repairs and fewer total losses.
Battery Concerns Drive Write-Offs
Most problems stem from electric vehicle batteries, which can account for up to 40% of a car’s value. These high-voltage systems are difficult to safely assess and repair after crashes.
Even minor collision damage often leads to vehicles being declared a total loss and written off.
A recent survey by Thatcham and the Centre for Economics and Business Research found that battery-related issues remained the primary concern for 44.6% of insurers and 41.7% of repair professionals.
The framework sets out steps to make EV batteries cheaper and easier to repair or replace. This would help keep more cars on the road and out of scrapyards.
Eight Points for Improvement
The blueprint’s recommendations range from making diagnostic systems widely accessible to ensuring batteries and components can be easily removed and replaced.
Dan Harrowell, principal engineer of advanced technologies at Thatcham Research, explained the economics:
“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%.”
He emphasized that continued collaboration between manufacturers, insurers and repairers is essential as more EVs hit the roads.
Other key recommendations include:
- Better battery protection against damage during crashes
- Modular construction allowing brackets and casing replacement instead of entire battery pack swaps
- Using fixings instead of adhesives to make removal easier
- Resettable safety loops that let emergency services cut high-voltage systems without permanent battery damage
- Moving charging ports to less vulnerable locations
Jonathan Hewett, Thatcham Research’s CEO, said the recommendations address a widespread problem:
“We’re seeing too many repairable vehicles written off simply because current designs don’t accommodate efficient assessment and repair processes.”
The blueprint draws from more than a decade of real-world EV impact assessments and repair procedures conducted in-house. Hewett noted that three-year-old EVs are being written off unnecessarily because of minor battery casing damage.
This impacts consumer confidence and undermines the sustainability credentials that make electrification important in the first place.
Proven Solutions Exist
Hewett emphasized that the eight recommendations are entirely achievable. These principles already work in conventional vehicles – resettable safety systems, accessible diagnostics, serviceable components.
There’s no technical reason why EVs can’t meet the same standards.
With EV batteries proving to have longer lifespans than initially expected, better repairability would cut costs and deliver a more sustainable industry.
Harrowell described the potential benefits: “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 shows that batteries can have very long usable lives that should be maximized through sustainable repair practices.
