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High-voltage Battery Recalls in Light EVs Electric vehicle recalls in 2025 were predominantly driven by high-voltage battery system failures. Reported issues included internal short circuits, overheating, manufacturing defects, and structural faults. Specific failure modes involved loose or improperly welded components, misaligned or pre-damaged cells, corrosion, water ingress, and battery management system BMS) detection errors. These issues posed risks of fire, thermal runaway, loss of drive power, and system shutdown during charging or operation, highlighting persistent vulnerabilities in battery design, assembly quality, and system integration.The most critical bottlenecks remain battery supply-chain reliability, battery pack qualification and validation, and installation quality at the vehicle level. The bar chart illustrates the distribution of EV battery-related recalls by the “mother companyˮ, consolidating recall activity across all subsidiaries and affiliated brands under a single corporate umbrella. This approach provides a view of cumulative recall exposure at the corporate group level.

2025 LIGHT EV RECALLS

Data Collection and Analysis Recall data is based on publicly available announcements from national and international safety authorities. Limitations: Public disclosures typically lack detailed root-cause analysis, relying instead on broad classifications such as thermal runaway, manufacturing defects, or installation issues (cause is difficult to attribute). Recall data alone is not sufficient to assess overall EV quality at the battery brand level.

Source: Data Collection and Analysis: Recall data aggregated from official international (OECD Global Recalls,ASEAN) and national safety recall databases around the world, including the US (US Consumer Product Safety Commission, National Highway Traffic Safety Administration), UK, China, Japan, South Korea, India, and Canada. Data range Jan 2025 to mid-Nov 2025. Includes formal recalls with disclosed unit volumes only. Data concentration reflects regions with higher reporting transparency North America, East Asia).

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