The Battery Manufacturing Question
Battery production is the most carbon-intensive part of making an EV, adding roughly 6,000-10,000 kg CO2e to the manufacturing footprint compared to a petrol car. A typical 60 kWh battery pack produces about 5,000-8,000 kg CO2e during manufacturing — primarily from mining lithium and cobalt, refining materials, and energy-intensive cell production. However, this upfront carbon cost is typically offset within 1.5-3 years of driving, depending on the electricity grid. Over a full vehicle lifetime (200,000+ km), the manufacturing premium becomes a small fraction of total lifecycle emissions.