Electric Vehicles: Safety, facts, and future

Electric vehicles have moved decisively from niche product to mainstream transportation choice. The statistics below reflect this pace of adoption.

Key adoption figures (based on 2025 statistics)

20.7M	Electric cars sold globally in 2025 showed a 20% increase in 2024. Source: Benchmark Mineral Intelligence, January 2026
25%+	Share of global new car sales that were electric in 2025 were more than 1 in 4. Source: International Energy Agency (IEA) Global EV Outlook 2025; IEA Executive Summary
43%	Share of Q1 2025 global auto sales represented by electrified vehicles (Battery Electric Vehicle – BEV + Plug-in Hybrid Electric Vehicle – PHEV + hybrid combined), up from 9% in 2019. Source: JATO data as reported by Visual Capitalist, 2025
Approx. 60%	Projected EV share of China’s new car sales in 2025 – China sold over 14 million EVs, more than the global total in 2023. Source: IEA Global EV Outlook 2025
33%	Year-on-year growth in European EV sales in 2025, with Germany (+48%) and the UK (+27%) leading. Source: Benchmark Mineral Intelligence, January 2026
5M bbl/day	Oil displaced per day globally by EVs in 2030 (IEA projection), an important energy security metric. Source: IEA Global EV Outlook 2025

Sales growth trajectory

The speed of transition is remarkable. Just the additional 3.5 million electric cars sold in 2024 compared to 2023 exceeded the entire global EV market in 2020.

Year	Global EV sales	Year-on-year change	EV share of new cars
2019	2.2 million	–	< 3%
2020	3.1 million	+41%	Approx. 4%
2021	6.6 million	+113%	Approx. 9%
2022	10.5 million	+59%	Approx. 14%
2023	14.0 million	+33%	Approx. 18%
2024	17.0 million	+21%	Approx. 20%
2025	20.7 million	+22%	> 25%

Regional market share (2025 estimates)

Region	2025 EV sales share	Key driver
China	Approx. 50% of global units	Government incentives; domestic manufacturing scale; Approx. 60% national market penetration
Europe	Approx. 25% of global units	EU emissions standards; expanding subsidies; 33% growth in 2025
United States	Approx. 10% of global units	IRA tax credits (partially removed late 2025); used EV market expanding
Rest of World	Approx. 15% of global units	Indonesia (+200%), Southeast Asia policy push, India growth
Australia	13.1% of new car saes (BEV: 8.3%)	Over 157,000 EVs sold in 2025 (up 38% on 2024); BEV sales passed 100,000 for the first time; Fringe Benefits Tax exemption on eligible EVs has been the single biggest driver of uptake since 2022. Source: Federal Chamber of Automotive Industries (FCAI) VFACTS (Vehicle Facts); Electric Vehicle Council, January 2026.

In Q1 2025, electrified vehicles (battery electric, plug-in hybrid, and hybrid combined) reached 43% of total global auto sales – up from just 9% in 2019. (Source: JATO / Visual Capitalist, 2025)

Electric vehicles offer several genuine structural safety advantages over conventional vehicles. However, the picture is nuanced – certain risks are higher in EVs, particularly for pedestrians and in collision severity for other road users due to weight.

Crash statistics comparing EVs with Internal Combustion Engine (ICE) vehicles are still maturing. EVs represent a small (but rapidly growing) share of total vehicle registrations. Studies can be affected by selection bias: early EV adopters tended to be careful, higher-income drivers. Interpret aggregate comparisons cautiously.
Note on the ‘40% lower injury probability’ figure: This is reported by insurance and legal analysis sources drawing on National Highway Traffic Safety Administration (NHTSA) test data, particularly Tesla’s strong New Car Assessment Program (NCAP) results. No single authoritative NHTSA study covers all EV models with this aggregate figure.

Key safety statistics

40%	Lower probability of occupant injury in an EV crash compared with an ICE vehicle, based on insurer analyses and NHTSA crash-test data. Source: Steinberg Law Firm EV Safety Study, 2024; LookupAPlate, Jan 2026
50%	More vehicle damage typically sustained by an EV in a crash, reflecting the weight and rigidity of battery packs. Source: LookupAPlate, January 2026; Steinberg Law Firm, 2024
33%+	Reduction in rollover risk for EVs compared to equivalent gas models, based on NHTSA NCAP data (e.g., Ford F-150 Lightning: 12.7% vs gas F-150: 19.1%). Source: Capital One / NHTSA NCAP rollover data, 2024
2x	Higher likelihood that pedestrians are struck by an EV (or hybrid) compared to a gas vehicle at low speeds, attributed to near-silent operation. Source: London pedestrian study; NHTSA 2024 NCAP review
5 star	Most modern EVs achieve five-star NHTSA/Euro NCAP ratings due to rigid battery floor structures and standard Advanced Driver Assistance Systems (ADAS). Source: AskAboutCars EV NCAP ratings review, 2025

Why EVs perform well in crash tests

• Rigid battery floor: The battery pack forms a reinforced underbody structure, distributing crash forces and lowering the centre of gravity. This reduces rollover risk and improves structural integrity in side impacts.
• Larger crumple zones: With no engine block up front, EVs can be designed with more effective frontal crumple zones to absorb collision energy before it reaches the cabin.
• Lower centre of gravity: The battery pack sits low in the vehicle, shifting weight toward the ground. This directly reduces the vehicle’s tendency to tip over in evasive manoeuvres.
• Advanced Driver Assistance Systems (ADAS): Most EVs are manufactured with ADAS as standard equipment, including Automatic Emergency Braking (AEB), lane-departure warning, and blind-spot monitoring – technologies that prevent crashes rather than merely managing their severity.
• Automatic high-voltage disconnect: In a significant collision, safety systems cut the high-voltage circuit to protect occupants and first responders from electrocution risk.

Key safety features in modern EVs

Feature	Description	Benefit
Acoustic Vehicle Alert System (AVAS)	Generates artificial sound at speeds below 19 mph (30 km/h). Mandatory in EU since 2021 and US since 2021.	Reduces pedestrian and cyclist collision risk in quiet environments
Automatic Emergency Braking (AEB)	Camera/radar detects imminent collision and applies brakes autonomously.	IIHS data shows up to 50% reduction in rear-end crashes
Battery Management System (BMS)	Monitors cell temperature, voltage, and state of charge in real time.	Prevents thermal runaway, extends battery life, alerts driver to faults
Blind-spot monitoring	Radar-based detection of vehicles in adjacent lanes.	Reduces lane-change collision risk
Crash disconnect system	Automatically isolates the high-voltage battery in a collision.	Protects occupants and first responders from electrocution
Regenerative braking	Motor acts as generator during deceleration, slowing the vehicle.	Reduces brake fade; often means less reliance on mechanical brakes

Areas where EV risk is higher

Pedestrian risks:

• A study conducted in London found pedestrians are approximately twice as likely to be struck by an electric or hybrid vehicle compared to a gasoline or diesel vehicle.
• A 2024 NHTSA-cited study reported a 40% increase in pedestrian accidents involving hybrid EVs compared to conventional vehicles.
• A separate study found EVs had a 35% higher accident rate than gas cars specifically during low-speed manoeuvres (parking lots, slow streets).
• Regulation response: AVAS (artificial sound systems) are now mandatory in new EVs in the EU (since July 2021) and the US (since September 2021) at speeds up to 19 mph / 30 km/h.
• Australia: AVAS became mandatory under Australian Design Rule 113/00 for all new-model electric, hybrid and hydrogen fuel-cell vehicles from 1 November 2025, and will extend to all remaining EV/hybrid models sold here from 1 November 2026. The rule, developed with input from Monash University’s Accident Research Centre and Vision Australia, requires an audible signal up to 20 km/h and was introduced partly because an estimated only 20% of quiet vehicles on Australian roads had AVAS fitted voluntarily beforehand.

Sources: London pedestrian study; DontGetHitTwice.com, February 2025; NHTSA NCAP 2024.

Weight differential

EVs are typically 25–33% heavier than equivalent petrol vehicles, with the extra mass concentrated in the battery pack. For example, the GMC Hummer EV carries 1,315 kg of batteries, giving it a total weight exceeding 4,000 kg. Research indicates that a 450 kg weight difference between vehicles in a two-car crash increases the risk of death for occupants of the lighter vehicle by approximately 47%. This is a relevant consideration for road safety as EVs become more prevalent.

Source: Steinberg Law Firm EV Safety Study, 2024; NTSB.

Fires involving electric vehicles attract significant media attention, which can distort public understanding of actual risk. This section presents the evidence-based picture.

Battery electric vehicles catch fire approximately 60 times less often than gasoline vehicles per 100,000 vehicles on the road.
When EV fires do occur, however, they present unique challenges: they can require thousands of gallons of water to extinguish, may re-ignite hours or days later, and release toxic gases.
Hybrids (which carry both a fuel tank and a battery pack ) have the highest fire rate of the three categories.

Fire incidents per 100,000 vehicles

Vehicle type	Fires per 100,000 vehicles	Relative risk vs BEV
Battery Electric Vehicle (BEV)	Approx. 25	Baseline (1x)
ICE vehicle	Approx. 1,530	Approx. 61x higher than BEV
Hybrid vehicle	Approx. 3,475	Approx. 139x higher than BEV

Fire frequency by miles driven

Metric	Battery EV (TEsla fleet data)	Gasoline (ICE) vehicle
Fires per billion miles driven	Approx. 5	Approx. 55
Miles driven per fire incident	Approx. 210 million	Approx. 19 million
Relative fire frequency	Baseline	Approx. 11x more frequent

Why EV fires are challenging when they do occur

• Thermal runaway: A damaged lithium-ion cell can trigger a chain reaction across adjacent cells, releasing enormous energy rapidly. This process can be difficult to interrupt once started.
• Water demand: EV battery fires can require 10,000-30,000 gallons of water or more to fully extinguish – far more than a typical gasoline vehicle fire. Some departments use immersion tanks for totalled EVs.
• Re-ignition risk: A battery that appears extinguished can re-ignite hours or even days later if damaged cells reignite. Vehicles should be kept away from structures and monitored.
• Toxic gases: Burning lithium-ion cells release hydrogen fluoride and other hazardous gases. Firefighters require appropriate Personal Protective Equipment (PPE) and breathing apparatus.
• Battery location: Packs are typically located under the vehicle floor, making access for suppression more difficult than for engine-bay fires.

How Battery Management Systems reduce fire risk

Modern EVs include a Battery Management System (BMS) specifically engineered to prevent the conditions that lead to thermal events. The BMS:

• Monitors the temperature, voltage, and current of every cell in real time.
• Limits charging to safe levels and prevents over-discharge.
• Activates cooling systems automatically when cell temperatures rise.
• Isolates faulty cells or modules from the rest of the pack.
• Alerts the driver and, in some models, sends notifications to the manufacturer’s monitoring systems.

Manufacturers including Tesla, BYD, and Hyundai have also implemented multi-layer structural protection around battery packs, with fire-resistant casing and venting systems designed to direct thermal events away from the passenger cabin.

In Australia, the Australasian Fire and Emergency Service Authorities Council (AFAC) has issued national doctrine and an online training package for EV and lithium-ion battery incidents, and fire services in each state (e.g. Fire and Rescue NSW) treat EVs and EV charging as a low-frequency, high-consequence special hazard under the National Construction Code. If you’re involved in or witness an EV fire in Australia, call Triple Zero (000) and always tell responders the vehicle is an EV.

Battery recycling is one of the most important sustainability challenges in the EV transition. This section covers what happens to EV batteries at end of life, current recycling rates, global capacity, and where to recycle your battery.

Market size and growth

$6.3B	Global EV battery recycling market value in 2025. Source: Precedence Research, December 2024
$73.2B	Projected market value by 2034, at a compound annual growth rate of 31.3%. Source: Precedence Research, December 2024
300+ GWh	Global lithium-ion battery recycling capacity in 2023, of which over 80% was in China. Source: IEA Global EV Outlook 2024
500K+ t	Estimated annual volume of end-of-life EV batteries in 2025, creating both an environmental challenge and economic opportunity. Source: Green Li-ion, Q4 2025 report

Current recycling rates – what the evidence actually shows

A 2023 academic analysis by Hans-Eric Melin et al. estimated the global battery recycling rate at approximately 59%. Regulatory data for specific regions varies. The honest answer is: the rate is uncertain and depends heavily on geography, battery type, and methodology. Both figures are noted here for transparency. What is undisputed is that infrastructure is being rapidly scaled up, and regulation is tightening requirements.

The variation in reported recycling rates reflects several real factors:

• China, which hosts approx. 65% of global EV battery recycling capacity, has a well-developed recycling infrastructure; its rates are considerably higher than the global average.
• In Europe and the US, recycling infrastructure is scaling rapidly but started from a lower base. The IEA reports that Europe and the US each held under 2% of global capacity in 2023.
• Production scrap (waste from battery manufacturing) is easier to recycle than end-of-life batteries, and dominates current recycling volumes. True end-of-life EV batteries are only beginning to reach recyclers at scale.
• Lead-acid batteries (used in all ICE vehicles and some EV 12V systems) achieve near-100% recycling rates due to decades of regulation – demonstrating what is achievable with the right regulatory framework.

The EV battery lifecycle

A well-managed EV battery goes through several stages before its materials are returned to the supply chain:

Stage	Description	Typical duration
1. Primary vehicle use	Battery powers the EV through daily operation.	8-15 years
2. Second-life repurposing	Batteries retaining 70–80%+ capacity are repurposed for stationary energy storage (home, grid, commercial).	5-10 additional years
3. Pre-processing	Battery is discharged, dismantled, and mechanically or thermally treated to produce ‘black mass’ (concentrated active materials).	Industrial process
4. Material recovery	Hydrometallurgical or pyrometallurgical processes recover metals from black mass.	Industrial process
5. Re-use in new cells	Recovered materials (lithium, cobalt, nickel, copper) re-enter the battery supply chain.	Ongoing/circular

Material recovery targets – EU Battery Regulation

The European Union’s Battery Regulation (effective from 2025) sets binding minimum recovery targets for critical materials:

Material	EU target from 2025	EU target from 2027	EU target from 2031
Cobalt	90% recovery	90% recovery	95% recovery
Copper	90% recovery	90% recovery	95% recovery
Nickel	90% recovery	90% recovery	95% recovery
Lithium	(35% target)	50% recovery	80% recovery
Lead	95% (established)	95%	95% recovery

Battery material availability from recycling (projections)

Year	Estimated recycled material available (kilotons)	End-of-life batteries as % of EV supply
2020	200 kt	–
2025	800 kt	Approx. 47%
2030	1,400 kt	Approx. 57%
2035	3,400 kt	Approx. 86%
2040	7,300 kt	Approx. 94%

Where to recycle your EV battery

Manufacturer take-back programmes

Most major EV manufacturers operate battery return programmes. Contact your dealer or the manufacturer’s sustainability team. Examples:

• Tesla: battery return via Tesla Service Centres; partners with recycling firms including Redwood Materials.
• Nissan: xStorage second-life battery programme; authorised end-of-life collection through dealer network.
• General Motors: GM partners with Li-Cycle for battery recycling; provides battery disposition guidance through Ultium Cells.
• BYD: operates internal recycling and remanufacturing facilities in China; expanding globally.
• In Australia: BYD Australia has a three-year agreement (from May 2025) appointing Melbourne-based recycler Livium (via its Envirostream subsidiary) as preferred recycler for its EV, commercial vehicle and battery-storage packs. Tesla, CATL and LG Energy Solution are also confirmed Envirostream/Livium clients for Australian and New Zealand operations.

Commercial recyclers (global)

Company	Region	Capability
Redwood Materials	USA	Full-cycle: collection, processing, material recovery; partners with multiple OEMs
Umicore	Europe / global	Pyrometallurgical and hydrometallurgical processes; one of the world’s largest battery recyclers
Li-Cycle	USA / Canada / Europe	Spoke-and-hub model; processes black mass into battery-grade materials
Green Li-ion	Global (Singapore-based)	Hydrometallurgical rejuvenation; produces battery-grade precursors directly
Ganfeng Lithium	China / global	Large-scale lithium recovery; vertically integrated with battery production
Contemporary Amperex Technology Co., Limited (CATL) (BRUNP – Guangdong Brunp Recycling Technology Co., Ltd.)	China	World’s largest battery maker operates its own closed-loop recycling arm
Livium (Envirostream)	Australia (Melbourne, Vic)	Australia’s first Environmental Protection Authority (EPA) licensed onshore lithium-ion recycler; wet-shredding to black mass, exported for metallurgical refining. Client base includes BYD, Tesla, CATL and LG Energy Solution. Western Australia start-up Renewable Metals is also commissioning a prototype plant at Kewdale (2,000 tonnes per year (t/yr), equivalent to Approx. 4,000 Electric Vehicle (EV) battery packs) from mid-2026.

Regulated collection points

• EU: Under the Battery Regulation, all Authorised Treatment Facilities (ATFs) must accept end-of-life batteries. National take-back schemes exist in all EU member states.
• Australia: The B-cycle Battery Stewardship Council scheme provides drop-off locations nationwide (find your nearest at b-cycle.org.au). B-cycle is authorised by the Australian Competition and Consumer Commission (ACCC) and now covers more than 5,400 drop-off points, with an estimated 95% of Australians living within a 15-minute drive of one. However, B-cycle was built primarily for portable/handheld batteries (household recycling rates rose from 25% in 2021 to 36% in 2024); large EV traction batteries are handled through a separate, still-developing commercial pathway (see 5.6 below). In March 2025, NSW passed the Product Lifecycle Responsibility Act, the first Australian law to make battery stewardship mandatory rather than voluntary, and national Extended Producer Responsibility reforms for lithium-ion batteries are expected by 2027.
• USA: The Battery Recycler of America, Call2Recycle, and manufacturer programmes accept batteries. The DOE’s ReCell Center funds advanced recycling research.
• UK: The Waste Batteries and Accumulators Regulations 2009 require producers to finance collection and recycling. Collection points available at major retailers.

Important:
Never dispose of EV batteries as general household or industrial waste. Damaged or improperly stored lithium-ion batteries can self-ignite.
If your EV battery is damaged (e.g. after a flood or collision), contact your manufacturer or emergency services for safe disposal guidance – do not attempt to move or store a damaged battery pack yourself.

These guidelines are drawn from manufacturer recommendations, NHTSA guidance, fire service advice, and best practice from the EV industry.

Charging safely

• Use only manufacturer-approved charging equipment or certified public chargers. Avoid damaged cables and unverified third-party chargers.
• For everyday driving, charge to 80% rather than 100%. Most manufacturers recommend keeping the battery between 20-80% state of charge to extend long-term battery health. Reserve 100% charges for long trips.
• Have home Level 2 (240V/7kW) chargers installed by a licensed electrician. Do not use standard extension cords for overnight charging from a wall socket.
• If you notice unusual heat, a burning smell, or swelling near the battery or charging port, stop charging immediately and move away from the vehicle. Contact your manufacturer’s emergency line and, if necessary, the fire service.
• Avoid charging a vehicle that has been in a significant collision until it has been inspected – the battery may have sustained internal damage not visible externally.
• Australia uses the Type 2 connector for Alternating Current (AC) (home/public) charging and CCS2 (Combined Charging System 2) for Direct Current (DC) fast charging – the same standard as Europe, but different from the US/Japan (CHAdeMO / NACS – North American Charging Standard), so check compatibility if you import or bring a vehicle from overseas. Home charger installations must comply with AS/NZS (Australian Standard/New Zealand Standard) 3000 wiring rules.

After a collision

• High-voltage systems are designed to automatically disconnect in a significant crash – but always treat the vehicle as potentially live until emergency services confirm otherwise.
• Do not attempt to access or open the battery compartment. In Australia, always call Triple Zero (000) first for any fire, injury or immediate danger, then use the local manufacturer emergency/roadside contact listed in your owner’s manual or vehicle app (for example, Tesla Australia’s in-app roadside assistance). You can also contact your manufacturer’s emergency line: Tesla Emergency: 1-877-798-3752; Nissan EV: 1-877-664-2738; check your owner’s manual for others. These two numbers are US toll-free lines and will not connect from Australia.
• Always inform emergency responders that the vehicle is an EV. Fire and rescue services follow specific high-voltage rescue protocols that differ from ICE vehicle procedures.
• A damaged EV should be parked outdoors, away from structures and other vehicles, for at least 24 – 72 hours following a crash, in case of delayed thermal events in the battery pack.
• If the battery begins to emit heat, smoke, or unusual sounds after a crash, move well away from the vehicle and call emergency services.

Pedestrian and community awareness

• Always enable your EV’s AVAS (pedestrian warning sound) system when the option is available. Do not modify or disable it – this is a legal requirement in the EU and US.
• Drive slowly and with heightened awareness in car parks, school zones, shared spaces, and pedestrian areas, where people may not hear your approach.
• As a pedestrian or cyclist: do not rely on hearing an approaching vehicle. Always look before crossing, especially in areas with high EV traffic such as urban centres and modern car parks.
• Parents and carers: educate children that modern vehicles – particularly EVs – may not make audible engine sounds. ‘Look and listen’ road safety messaging should become ‘look and look again’ in EV environments.

Battery health and end-of-life

• Have your battery health assessed by a certified technician at regular service intervals. Most EVs display state-of-health (SoH) data in the vehicle’s app or infotainment system.
• If your EV battery’s capacity has dropped significantly (typically below 70–80% of original capacity), consult your manufacturer about warranty, replacement, or recycling options before the battery fails completely.
• Second-life options: many manufacturers and energy companies offer buy-back or repurposing programmes for batteries with remaining capacity. These extend useful life before final recycling.
• When your battery reaches true end of life, contact your manufacturer, an authorised treatment facility, or a certified battery recycler. Do not dispose of EV batteries in general waste, skips, or landfill.
• In Australia: your dealer or manufacturer is the first port of call for a full EV traction battery, which will typically be routed to a commercial recycler such as Livium/Envirostream rather than a household B-cycle drop-off point (B-cycle is designed for small portable and power-tool batteries, not vehicle traction packs). For council kerbside collections, never place any lithium-ion battery – including power tool, e-bike or scooter batteries – in your household recycling or general waste bin; damaged or crushed batteries are a leading cause of waste-truck and processing-facility fires in Australia.

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