Castrol has recently conducted a new study that reveals some of the factors which most Indian drivers would consider before switching to an EV. the new study draws on the views of consumers, fleet managers and automotive industry leaders from across India to reveal the factors driving EV buying decisions. 

According to the new study, on average for consumers in India, a price point of ₹23,00,000 (or $31,000), a charge time of 35 minutes and a range of 401 kilometers (from a single charge) represent the ‘tipping points’  to achieve mainstream EV adoption. The research also estimates that the annual EV market in India could be worth $2 billion by 2025 if all three tipping points are met, pointing to a possible EV-powered low-carbon recovery for the automotive industry.
Based on research from eight of the world’s most important EV markets, Castrol’s study examines five critical challenges that should be addressed to promote further growth in the EV market - highlighting the differing priorities for consumers and fleet managers. 
Key findings from the opinion research, which was conducted from December 2019 to January 2020, include:
 
EV sales to power up in 2022
On average, consumers in India said they would consider purchasing an EV by 2022. This is two years earlier than the global average (2024). However, two thirds (67%) of consumers in India said they are adopting a ‘wait and see’ approach. Over 40% of fleet managers said they are waiting for competitors to make the switch before they do.
 
Affordability is a deal breaker
Price is the number one priority for consumers in India with 67% of those surveyed saying that EVs are currently beyond their budget. The ₹23,00,000 (or $31,000) ‘tipping point’ for consumers in India is lower than the global average of ₹27,00,000 (or $36,000).
 
The study also finds that misconceptions about maintenance costs could be stopping consumers making the switch: 83% of Indian consumers say that these costs were preventing them from buying a fully electric car. This suggests that many consumers are unaware that the overall average cost of ownership of an EV over its lifetime tends to be lower than an ICE vehicle.
 
Need for instant recharge
Charge time was identified as the second most important challenge to the mainstream adoption of EVs, and consumers in India said they require an average charge time of 35 minutes before they would consider purchasing an EV. This is several minutes longer than the global average of 31 minutes. Nearly three quarters (72%) of those questioned believe EVs will only dominate on the roads once they can charge in a similar amount of time as it takes to refuel an internal combustion engine (ICE) vehicle. 
 
Call for higher range per charge
Range was ranked third on the priority list, with 64% of Indian drivers agreeing it is a significant barrier to mainstream adoption of EVs. On average, they expect a range of 401 km (from a single charge), approximately equivalent to the distance between Ahmedabad and Indore. This is significantly lower than the global ‘tipping point’ range of 469 km. However, around a third of drivers in India said they mainly use their car for commuting or short journeys, so this suggests that ‘range anxiety’ may only be partly driving their preference.
 
Mandhir Singh, chief executive officer at Castrol said: “The automotive industry has already demonstrated what it can achieve in response to the coronavirus crisis, turning its capabilities to producing much needed medical equipment. With EV technology constantly improving, the challenge now will be to drive a low-carbon recovery and accelerate the EVolution as quickly as possible. Castrol has been working with the automotive industry to develop unique e-Fluid technology to support EVs, from battery coolant e-fluid, e-greases and transmission fluids.
 
Bringing down the cost and charge time for electric vehicles while increasing range, infrastructure and vehicle choice will be critical to persuading consumers to make the switch to EVs.”

Sandeep Sangwan, managing director at Castrol India Ltd said: “Castrol’s global research shows that consumers are positive about making the switch to electric; buyers in India are keen to do so earlier than those in other markets. Although consumers in India are seeking a lower price point than consumers in other countries, they are also willing to accept a slightly longer charge time and a slightly shorter range. These market-specific nuances are important; Accelerating the EVolution provides a clear roadmap for the industry to help support the transition to accelerate mainstream adoption of EVs in India and around the world.”

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Researchers at Chalmers University of Technology, in collaboration with industry partners, have published a study in Nature Communications demonstrating that reconfigurable battery pack architectures can extend electric vehicle battery operational life by more than 20 percent under specific conditions.

In conventional electric vehicle battery packs, cells are wired in a fixed series configuration, meaning the weakest cell dictates the overall capacity, performance and lifespan of the entire pack. The architecture evaluated by the Chalmers engineering team uses integrated electronic switches and a centralised battery management system to monitor individual cells or cell groups. When a cell experiences accelerated degradation or reduced capacity, the system bypasses the degraded unit while electric current continues to flow through the remaining functional cells.

Albert Skegro, a PhD student at the Department of Electrical Engineering at Chalmers University of Technology, said, "They must all move at the pace of the slowest person and stop when that person stops, regardless of how much energy the others have left. With the architecture we have modelled, the battery can instead bypass the cell that is causing problems and continue using the remaining cells."

Changfu Zou, Professor at the Department of Electrical Engineering at Chalmers, said, "Reconfiguration is not an on-or-off choice. It is a spectrum. Where a manufacturer chooses to position itself on that spectrum determines how much of the potential benefit can be realised."

In a representative modelling scenario featuring an 80 kWh battery pack driven 12,000 kilometres annually over an 18.8-year vehicle lifespan, the reconfigurable system deferred battery replacement by approximately 14 months. The researchers noted that the technology yields the highest performance gains in high-voltage vehicles, including 400-volt and 800-volt electric passenger cars and commercial trucks, where higher cell counts in series increase the statistical probability of individual cell variance.

A techno-economic analysis included in the study determined that implementing cell-level switching hardware increases initial pack production costs by approximately nine per cent based on prototype-scale volumes of 1,000 units. The researchers identified an economic break-even threshold at a 12 percent cost increase, noting that volume manufacturing would lower component costs and increase financial viability for fleet operators and private owners. While prototype applications such as Volvo Cars' SmartCell concept and experimental road vehicles exist, mass-production vehicles using reconfigurable battery packs are yet to enter the commercial market.

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Jakson Green Vehicles has selected Dassault Systèmes’ cloud-based 3DEXPERIENCE platform to manage the design and development of its electric vehicles.

The implementation establishes a collaborative engineering framework to maintain digital continuity across the product development lifecycle. By connecting internal teams and external suppliers, the platform automates workflows, standardises component libraries and manages engineering change requests during early-stage product design. Virtual twin capabilities allow the vehicle manufacturer to conduct virtual validation testing to resolve structural and systems design issues prior to physical manufacturing.

Deepak Thakur, CEO, Jakson Green Vehicles, said, "Using Dassault Systèmes’ 3DEXPERIENCE Platform enables us to apply a collaborative approach and re-engineer our product lifecycle from the ground up. Through this transition from legacy environments to a unified digital thread, it enables strong R&D to achieve twin objectives; accelerated time-to-market and mitigated development costs. This partnership is helping us to transform the early-stage innovation and product design processes."

Deepak NG, Managing Director – India, Dassault Systèmes, said, "As India continues its dynamic growth trajectory, virtual twin technology serves as a powerful catalyst for sustainable innovation, empowering industries to rethink how they design, produce and operate."

The software adoption forms part of Jakson Green Vehicles' plan to build urban zero-emission mobility vehicles and infrastructure across India.

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UK-headquartered energy technology company Gelion has entered into a material transfer agreement with a top 15 global automotive original equipment manufacturer to assess its NES cathode platform for future electric vehicle battery applications.

Under the terms of the agreement, Gelion will supply its sulfur-based cathode active material, coated cathodes and liquid electrolyte to the automotive partner. The manufacturer will evaluate the platform in both liquid and solid electrolyte cell configurations, testing compatibility across lithium metal and graphitic anode pathways targeting luxury and mass-market vehicle applications. The technology is designed to serve as a drop-in cathode material capable of integration into existing battery manufacturing lines without re-tooling.

Matt Wood, Chief Executive Officer, Gelion, said, "Our priority markets are commercial & defence drones, EVs and devices. We are honoured to be working with these major global automotive OEMs, and today’s announcement marks further progress towards the adoption of our technology and the generation of commercial revenues via funded programmes and eventually license and royalty revenue in the global EV market, alongside some of the industry’s leading companies."

"The growing engagement from global EV manufacturers reinforces the potential and attractiveness of our NES™ technology. This momentum is also mirrored in our agreements and partnerships across drones and devices, while our work with Tier 1 materials suppliers is advancing the scale-up of our unique, patented battery materials," Wood added.

The agreement expands Gelion’s ongoing industry testing programs with automotive manufacturers, extending the assessment of its sulfur-based cathode platform across liquid and solid battery systems.

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Honda R&D, a subsidiary of Honda Motor Co., has developed underlying technology for a magnetic coupling wireless power transfer road system in partnership with Taisei Corporation and Taisei Rotec Corporation.

The system enables wireless in-motion charging for electric vehicles, including passenger cars and heavy commercial fleets. The partners plan to initiate demonstration testing on public roads starting in FY2027.

The technology integrates high-power-density receiver and transmitter units from Honda with a high-response direct current power supply system from Taisei and road-embedding construction techniques from Taisei Rotec. By supplying power to electric vehicles while in motion, dynamic wireless power transfer reduces the need for stationary charging infrastructure. The initial commercial focus targets logistics and transport operations, where continuous operation offers economic benefits.

The ground assembly embedded in the roadway combines the inverter and coil into a single unit designed to connect via direct current distribution. This design reduces component counts, simplifies wiring and supports installation into existing road surfaces through standard milling methods. The road pavement structures are engineered to withstand continuous traffic loads from vehicles weighing up to 20 tonnes (20,000kg).

Testing conducted at Taisei Group’s T-FIELD facility in Satte verified system stability and structural durability. Starting in late 2026, the companies will build a test roadway at T-FIELD Tamura to evaluate long-term durability under one million wheel-load cycles, measure power transfer efficiency at outputs up to 150 kW and analyse electromagnetic shielding.

The partnership will also join the Tateyama Expressway demonstration project managed by East Nippon Expressway Company starting in 2027.

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