GM, Ford Need Electric-Car Batteries, but Take Different Paths to Get Them


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Auto makers, pumping billions of dollars into developing electric cars, are now facing a critical choice: get more involved with manufacturing the core batteries or buy them from others.

Batteries are one of an electric vehicle’s most expensive components, accounting for between a quarter and a third of the car’s value. Driving down their cost is key to profitability, executives say.

But whereas the internal combustion engine traditionally has been engineered and built by auto makers themselves, battery production for electric cars is dominated by Asian electronics and chemical firms, such as LG Chem Ltd. and Panasonic Corp. , and newcomers like China’s Contemporary Amperex Technology Co.

California, the U.S.’s largest car market, said last month it would end the sale of new gasoline- and diesel-powered passenger cars by 2035, putting pressure on the auto industry to accelerate its shift to electric vehicles.

The race to lock in supplies for electric cars has auto makers taking varied paths.

While most make the battery pack, a large metal enclosure often lining the bottom of the car, they also need the cells that are bundled together to form the core electricity storage.

Tesla several years ago opened its Gigafactory in Nevada to make batteries with Panasonic, which in the shared space would produce cells for the packs. The electric-car maker wanted to secure production specifically for its own models and lower manufacturing and logistics costs.

Now it is looking to in-source more of that production.

While Tesla will continue to buy cells from Panasonic and other suppliers, it is also working on its own cell technology and production capabilities to ensure it can keep up with demand for its cars, said Chief Executive Elon Musk last month.

Following Tesla’s lead, General Motors Co. and South Korea’s LG Chem are putting $2.3 billion into a nearly 3-million-square-foot factory in Lordstown, Ohio, which GM says will eventually produce enough battery cells to outfit hundreds of thousands of cars each year.

In Europe, Volkswagen AG is taking a similar path, investing about $1 billion in Swedish battery startup Northvolt AB, including some funding to build a cell-manufacturing plant in Salzgitter, Germany, as part of a joint venture.

Others like Ford Motor Co. and Daimler AG are steering clear of manufacturing their own cells, with executives saying they prefer contracting with specialized battery makers.

Supply-chain disruptions have already challenged some new model launches and put projects at risk, auto makers say.

For instance, Ford and VW have agreements in place with SK Innovation to supply battery cells for future electric-vehicle models. The South Korean company is building a factory in Georgia to help meet this demand, but a fight over trade secrets has put the plant’s future in jeopardy and could disrupt new model launches, both auto makers have said in legal filings.

GM executives say the risk of relying on suppliers has pushed them to produce their own battery cells, albeit with LG Chem.

“We’ve got to be able to control our own destiny,” said Ken Morris, GM’s vice president of electric vehicles.

Bringing the manufacturing in house will give the company more control over the raw materials it purchases and the battery-cell chemistry, Mr. Morris said.

But establishing production, even in a joint venture, is a costly proposition, and it won’t necessarily ensure a timely supply of cells. There are also risks with making big investments on one battery technology because a breakthrough could make it obsolete.

Ford cites those factors in deciding against a similar investment for now.

The company sees the industry’s conventional model of contracting with independent suppliers to build parts as better suited to its battery-cell needs, Ford executive Hau Thai-Tang told analysts in August.

“We have the competitive tension with dealing with multiple suppliers, which allows us to drive the cost down,” Mr. Thai-Tang said, adding that the company expects to pay prices for cells in line with GM and Tesla.


Meanwhile, Ford can leave the capital-intensive task of conducting the research and setting up manufacturing facilities to the battery companies, Mr. Thai-Tang said.

Germany’s Daimler has tried both strategies.

The car company made its own lithium-ion cells through a subsidiary until 2015. But the capital required to scale up was better spent elsewhere, said Ola Källenius, Daimler’s chief executive officer.

The auto maker instead signed long-term supply agreements with Asian companies like Chinese battery-maker CATL and Farasis Energy (Ganzhou) Co., which Daimler invested in last year.

The company has said it is spending roughly $23.6 billion on purchase agreements but keeping its battery research in-house.

“Let’s rather put that capital into what we do best, cars,” Mr. Källenius said.

Related News

What the U.S. can learn from the U.K. about wind power

As President Joe Biden’s administration puts its muscle behind wind power with plans to develop large-scale wind farms along the entire United States coastline, the administration can look at how the windiest nation in Europe is transforming its energy grid for an example of how to proceed.

In the search for renewable sources of energy, the United Kingdom has embraced wind power. In 2020, the country generated as much as 24 percent of its electricity from wind power — enough to supply 18.5 million homes, according to government statistics. 

With usually reliable winds, the U.K. currently has the highest number of offshore turbines installed in the world, with China at a close second.

Experts and industry leaders say it offers valuable lessons on creating a viable market for wind power at the ambitious scale the Biden administration hopes to meet in order to confront climate change and help transition the U.S. economy to renewable energy.

“The U.S. is going to benefit hugely from the early investment that European governments have put into offshore wind,” said Oliver Metcalfe, a wind power analyst at BloombergNEF in London, an independent research group.

Big American plans
On Oct. 13, the White House announced plans to lease federal waters off of the East and West Coasts and Gulf of Mexico to develop commercial wind farms.

The move is part of Biden’s goal to have 30,000 megawatts of offshore wind power produced in the United States by 2030. The White House says that would generate enough electricity to power more than 10 million homes and in the process create 77,000 jobs. 

But there is a chasm between where the U.S. is now and where it wants to be within the next decade when it comes to offshore wind power.

“We’re the first generation to understand the science and implications of climate change and we’re the last generation to be able to do something about it.”

The U.S. is not new to wind power; onshore wind in states such as Texas, Oklahoma and Iowa supplied 8.2 percent of the country’s total electricity generation in 2020, according to the U.S. Department of Energy. 

But despite its long coastlines, offshore wind has been a largely untapped resource in the U.S. With a population of about 332 million people, the U.S. currently has just two operational offshore wind farms — off Rhode Island and Virginia — with the capacity to produce 42 megawatts of electricity between them.  

In contrast, the U.K., with a population of 67 million people, has 2,297 offshore wind turbines with the capacity to produce 10,415 megawatts of electricity.

Power station or a park?
Just outside of central Glasgow, the host city for the U.N. climate change conference known as COP26, the fruits of years of effort to move away from fossil fuels can be seen and heard

Whitelee Windfarm, the U.K.’s largest onshore wind farm, spreads across 30 square miles on the Eaglesham Moor and includes more than 80 miles of trails for walking, cycling and horseback riding.

With its 539 megawatt capacity, it generates enough electricity for 350,000 homes — more than half the population of Glasgow. 

On a recent gusty fall day, Ian and Fiona Gardner, both 71, were walking their dogs among the wind farm’s 360-foot-tall turbines  

“This is a major contribution to Scotland, to become independent from oil by 2035,” Ian Gardner, an accountant, said. 

Thanks to the rapid technological advances in turbine technology, this wind farm that was completed in 2009, is now practically old school. The latest crop of onshore turbines typically generate double the current capacity of Whitelee’s turbines.

“It took us 20 years to build 2 gigawatts of power. And we’re going to double that in five  years,” said McQuade, an economist. “We can do that because machines are big, efficient, cheap and the supply chain is there.” 

The biggest operational offshore wind farm in the world right now, Hornsea Project One, is about 75 miles off England’s Yorkshire coast in the North Sea.

Owned and operated by Orsted, a former Danish oil and gas giant, in partnership with Global Infrastructure Partners, its 174 turbines have the capacity to generate 1.2 gigawatts — enough to power over 1 million homes and roughly equivalent to a nuclear power plant. 

Benj Sykes, Vice President of U.K. Offshore Wind at Orsted, called Hornsea One a “game changer” in a recent phone interview, citing it as an example of how the industry has scaled up its output to compete with traditional power plants.

But massive projects like Hornsea One took decades to get up and running, as well as government help. According to Malte Jansen, a research associate at the Centre of Environmental Policy at Imperial College London, the British government helped facilitate a “paradigm shift” in renewable energy in 2013.

The electricity market reform policy set up a framework to incentivize investment in offshore wind farms by creating an auction system that guarantees electricity prices to developers in 15-year contracts. 

This means there is no upside in terms of market price fluctuation, but there is no downside either. The policy essentially “de-risked the investment,” Jansen said.

The state contracts allowed the industry to innovate and learn how to develop even larger and more efficient turbines with blades that stretch as long as 267 feet, about three-quarters the size of a U.S. football field. 

While this approach helped companies and investors, it will also have an unintended beneficiary — the U.S., Metcalfe from BloombergNEF said. 

Developers are “taking the lessons they’ve learned building projects in Europe, the cost reductions that they’ve achieved building projects in Europe and are now bringing those to the U.S. market,” he said.

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Battery energy storage system eyed near Woodstock

A Quebec-based renewable energy company is proposing to build a battery energy storage system in Oxford County near Woodstock.

The Oxford battery energy storage project put forward by Boralex Inc., if granted approval, would be ready for commercial operation in 2028. The facility would be in the Township of South-West Oxford, but also would serve Woodstock businesses and residences due to the city’s proximity to the site.

Battery storage systems charge when energy sources produce more energy than customers need, and discharge during peak demand to provide a reliable, steady supply of energy.

Darren Suarez, Boralex’s vice-president of public affairs and communications in North America, said, “The system we’re talking about is a very large battery that will help at times when the electric grid has too much energy on the system. We’ll be able to charge our batteries, and when there’s a need, we can discharge the batteries to match the needs of the electric grid.”

South-West Oxford is a region Boralex has pinpointed for a battery storage project. “We look at grid needs as a whole, and where there is a need for battery storage, and we’ve identified this location as being a real positive for the grid, to help with its stability,” Suarez said.

Suarez could not provide an estimated cost for the proposed facility but said the project would add about 75 jobs during the construction phase. Once the site is operational, only one or two employees will be necessary to maintain the facility, he said.

Boralex requires approval from the Independent Electricity System Operator (IESO), the corporation that co-ordinates and integrates Ontario’s electricity system, for the Oxford battery energy storage project.

Upon approval, the project will connect with an existing Hydro One transmission line located north of the proposed site. “[Hydro One] has a process to review the project and review the location and ensure we are following safety standards and protocols in terms of integrating the project into the grid, but they are not directly involved in the development of the project itself,” Suarez said.

The proposal has been presented to South-West Oxford council. South-West Oxford Mayor David Mayberry said, “(Council) is still waiting to see what permits are necessary to be addressed if the proposal moves forward.”

Mayberry said the Ministry of Natural Resources and Forestry also would be reviewing the proposed project.

Thornton Sand and Gravel, the location of the proposed facility, was viewed positively by Mayberry. “From a positive perspective, they’re not using farmland. There is a plus we’re not using farmland, but there is concern something could leak into the aquifer. These questions need to be answered before it can be to the satisfaction of the community,” Mayberry said.

An open house was held on Sept. 14 to provide information to residents. Suarez said about 50 people showed up and the response was positive. “Many people came out to see what we planned for the project and there was a lot of support for the location because of where it actually is, and how it integrates into the community. It’s considered good use of the land by many of the people that were able to join us on that day,” Suarez said.

The Quebec-based energy company has been operating in Ontario for nearly 15 years and has wind farms in the Niagara and Chatham-Kent regions.

Boralex also is involved in two other battery storage projects in Ontario. The Hagersville project is a 40-minute drive northwest of Hamilton, and the other is in Tilbury, a community in Chatham-Kent. Commercial operation for both sites is planned to begin in 2025.

South-West Oxford and Woodstock will see some financial benefits from the energy storage system, Suarez said.

“It will help to stabilize energy costs. It will contribute to really shaving the most expensive energy on the system off the system. They’re going to take electricity when it’s the least costly and utilize that least costly energy and displace the most costly energy.”

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Biden's proposed tenfold increase in solar power would remake the U.S. electricity system

President Joe Biden has called for major clean energy investments as a way to curb climate change and generate jobs. On Sept. 8, 2021, the White House released a report produced by the U.S. Department of Energy that found that solar power could generate up to 45% of the U.S. electricity supply by 2050, compared to less than 4% today. The Conversation asked Joshua D. Rhodes, an energy technology and policy researcher at the University of Texas at Austin, what it would take to meet this target.

Why such a heavy focus on solar power? Doesn’t a low-carbon future require many types of clean energy?
The Energy Department’s Solar Futures Study lays out three future pathways for the U.S. grid: business as usual; decarbonization, meaning a massive shift to low-carbon and carbon-free energy sources; and decarbonization with economy-wide electrification of activities that are powered now by fossil fuels.

It concludes that the latter two scenarios would require approximately 1,050-1,570 gigawatts of solar power, which would meet about 44%-45% of expected electricity demand in 2050. For perspective, one gigawatt of generating capacity is equivalent to about 3.1 million solar panels or 364 large-scale wind turbines.

The rest would come mostly from a mix of other low- or zero-carbon sources, including wind, nuclear, hydropower, biopower, geothermal and combustion turbines run on zero-carbon synthetic fuels such as hydrogen. Energy storage capacity – systems such as large installations of high-capacity batteries – would also expand at roughly the same rate as solar.

One advantage solar power has over many other low-carbon technologies is that most of the U.S. has lots of sunshine. Wind, hydropower and geothermal resources aren’t so evenly distributed: There are large zones where these resources are poor or nonexistent.

Relying more heavily on region-specific technologies would mean developing them extremely densely where they are most abundant. It also would require building more high-voltage transmission lines to move that energy over long distances, which could increase costs and draw opposition from landowners.

Is generating 45% of U.S. electricity from solar power by 2050 feasible?
I think it would be technically possible but not easy. It would require an accelerated and sustained deployment far larger than what the U.S. has achieved so far, even as the cost of solar panels has fallen dramatically. Some regions have attained this rate of growth, albeit from low starting points and usually not for long periods.

The Solar Futures Study estimates that producing 45% of the nation’s electricity from solar power by 2050 would require deploying about 1,600 gigawatts of solar generation. That’s a 1,450% increase from the 103 gigawatts that are installed in the U.S. today. For perspective, there are currently about 1,200 gigawatts of electricity generation capacity of all types on the U.S. power grid.

The report assumes that 10%-20% of this new solar capacity would be deployed on homes and businesses. The rest would be large utility-scale deployments, mostly solar panels, plus some large-scale solar thermal systems that use mirrors to reflect the sun to a central tower.

Assuming that utility-scale solar power requires roughly 8 acres per megawatt, this expansion would require approximately 10.2 million to 11.5 million acres. That’s an area roughly as big as Massachusetts and New Jersey combined, although it’s less than 0.5% of total U.S. land mass.

I think goals like these are worth setting, but are good to reevaluate over time to make sure they represent the most prudent path.

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France's new EV incentive rules toughen market for Chinese cars

France's revamped rules on consumer cash incentives for electric car purchases favour vehicles made in France and Europe over models manufactured in China, a government list of eligible car types published recently has showed.

Some 65% of electric cars sold in France will be eligible for the scheme, which from Friday will include new criteria covering the amount of carbon emitted in the manufacturing of an electric vehicle (EV).

The list of eligible models includes 24 produced by Franco-Italian group Stellantis (STLAM.MI) and five by French carmaker Renault (RENA.PA). Elon Musk's Tesla (TSLA.O) Model Y will be eligible but not its Model 3.

Electric vehicle brand MG Motors, owned by China's SAIC, said it expects the new rules to weigh on the French EV market.

"There are cars that will entirely lose their competitiveness", an MG spokesperson told Reuters, adding that the brand had decided not to apply for the bonus scheme for its MG4 model because it was "designed to exclude us".

French Finance Minister Bruno Le Maire hailed what he called the new rules' incentive for automakers to reduce their carbon footprint.

"We will no longer be subsidising car production that emits too much CO2," he said in a statement.

President Emmanuel Macron's government has wanted to make French and European-made EVs more affordable for domestic consumers relative to cheaper vehicles produced in China.

The average retail price of an EV in Europe was more than 65,000 euros ($71,000) in the first half of 2023, compared with just over 31,000 euros in China, according to research by Jato Dynamics.

The French government already offered buyers a cash incentive of between 5,000 and 7,000 euros to get more electric cars on the road, at a total cost of 1 billion euros ($1.1 billion) per year.

However, in the absence of cheap European-made EVs, a third of all incentives are going to consumers buying EVs made in China, French finance ministry officials say. The trend has helped spur a surge in imports and a growing competitive gap with domestic producers.

China's auto industry relies heavily on coal-generated electricity, meaning many Chinese-made EVs will henceforth not qualify.

The Ademe agency overseeing the process studied the eligibility of almost 500 EV models and their variants to include in the scheme.

Dacia, the low-cost Renault brand, saw its Spring model imported from China excluded from the list.

Tesla's Model 3 is made in China. The Model Y, which is larger and more expensive, is made mainly in Berlin and was the top selling EV in France over the first 11 months of the year.

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4 European nations to build North Sea wind farms

Four European Union countries plan to build North Sea wind farms capable of producing at least 150 gigawatts of energy by 2050 to help cut carbon emissions that cause climate change, Danish media have reported.

Under the plan, wind turbines would be raised off the coasts of Belgium, the Netherlands, Germany and Denmark, daily Danish newspaper Jyllands-Posten said.

The project would mean a tenfold increase in the EU's current offshore wind capacity.

“The North Sea can do a lot," Danish Prime Minister Frederiksen told the newspaper, adding the close cooperation between the four EU nations "must start now.”

European Commission President Ursula von der Leyen, German Chancellor Olaf Scholz, Dutch Prime Minister Mark Rutte and Belgian Prime Minister Alexander De Croo are scheduled to attend a North Sea Summit on Wednesday in Esbjerg, 260 kilometers (162 miles) west of Copenhagen.

In Brussels, the European Commission moved Wednesday to jump-start plans for the whole 27-nation EU to abandon Russian energy amid the Kremlin’s war in Ukraine. The commission proposed a nearly 300 billion-euro ($315 billion) package that includes more efficient use of fuels and a faster rollout of renewable power.

The investment initiative by the EU's executive arm is meant to help the bloc start weaning themselves off Russian fossil fuels this year. The goal is to deprive Russia, the EU’s main supplier of oil, natural gas and coal, of tens of billions in revenue and strengthen EU climate policies.

“We are taking our ambition to yet another level to make sure that we become independent from Russian fossil fuels as quickly as possible,” von der Leyen said in Brussels when announcing the package, dubbed REPowerEU.

The EU has pledged to reduce carbon dioxide emissions by 55% compared with 1990 levels by 2030, and to get to net zero emissions by 2050.

The European Commission has set an overall target of generating 300 gigawatts of offshore energy of by 2050.

Along with climate change, the war in Ukraine has made EU nations eager to reduce their dependency on Russian natural gas and oil. In 2021, the EU imported roughly 40% of its gas and 25% of its oil from Russia.

At a March 11 summit, EU leaders agreed in principle to phase out Russian gas, oil and coal imports by 2027.

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Why a green recovery goes far deeper than wind energy

THE “green recovery” joins the growing list of Covid-era political maxims, suggesting a bright and environmentally sustainable post-pandemic future lies ahead.

The Prime Minister once again alluded to it recently when he expressed his ambition to see the UK become the “world leader in clean wind energy”. In his typically bombastic style, Boris Johnson declared that everything from our kettles to electric vehicles will be powered by “breezes that blow around these islands” by the next decade.

These comments create a misleading impression about how we can achieve a green recovery. While wind turbines have a key role to play, they are just one part of a comprehensive solution requiring a far more in-depth focus on how and why we use energy. We must concentrate our efforts and resources on reducing our overall consumption and increasing energy capture.

This includes making significant energy efficiency improvements to the buildings where we live and work and grasping the lessons of lockdown to ensure we operate in a more effective and less environmentally-damaging fashion. Do we really want to return to a world where people commute daily half way across the country for work or fly to New York for a two-hour meeting?

Businesses will need to adapt to new ways of operating outwith the traditional nine-to-five working week to reduce congestion and pollution levels. To make this possible requires Government investment in critical areas such as public transport and digital infrastructure across all parts of Scotland to decentralise the economy and enable more people to live and work outside the main cities.

A Government-supported green recovery must rest on making it financially viable for businesses to manufacture here to reduce our reliance on imported goods. This includes processing recycleable materials here rather than shipping them abroad. It also means using locally generated energy to support local jobs and industry. We miss a trick if Scotland simply becomes a power generator for the rest of the UK.

MOVING transport from fossil fuels to renewable fuels will require a step-change that also requires support across all levels. The increased use of electric vehicles and hydrogen fuel cells are all encouraging developments, but these will rely on investment in infrastructure throughout the country if we’re to achieve significant benefits to our environment and our economy.

This brings us to the role of onshore wind power; still the cheapest form of renewable energy. Repowering existing sites with newer and more efficient turbines will certainly increase capacity rapidly, but we must also invest into development projects that will further enhance the capacity and efficiency of existing equipment. This includes improving on the current practice of the National Grid paying operators to switch off wind turbines when excess electricity is produced and instead developing new and innovative means to capture this energy. Government-primed investment into battery storage could help ensure we achieve and further reduce our reliance on traditional, non-sustainable sources.

We need a level playing field so that all forms of energy are judged on their lifetime cost in terms of emissions as well as construction and decommissioning costs to ensure fiscal incentives are applied on a fairer basis.

Turning the maxim of a green recovery into reality will require more than extra wind turbines. We need a significant investment and commitment from business and government to limit existing emissions and ensure we capture and use energy more efficiently.

Andy Drane is projects partner and head of renewables at law firm Davidson Chalmers Stewart.

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