The Missing Middle in Electric Commercial Vehicles
General Motors President Mark Reuss recently highlighted a significant gap in the electric vehicle market: the absence of mid-size electric vans. While compact and large electric commercial vehicles have begun to emerge, the middle segment remains largely unaddressed due to a complex interplay of technological and economic factors.
Battery Technology Limitations
The core challenge lies in current battery systems. Mid-size vans require a specific balance of capacity, weight, and cost that existing battery technology struggles to deliver. To achieve the range and payload capacity commercial operators demand, batteries would need to be disproportionately large and heavy, compromising cargo space and vehicle efficiency. Additionally, the thermal management and safety systems required for such battery packs add further complexity and expense.
Economic Viability Concerns
From a manufacturing perspective, developing a mid-size electric van presents significant economic hurdles. The research, development, and production costs for a vehicle in this category are substantial, yet the potential price point may not align with market expectations. Businesses considering fleet electrification often calculate total cost of ownership meticulously, and if the upfront investment is too high compared to the operational savings, adoption stalls. This creates a challenging business case for automakers to justify the required investment.
Market and Infrastructure Factors
Beyond the vehicle itself, the supporting ecosystem influences this gap. Charging infrastructure for commercial vehicles, particularly for businesses operating from depots or requiring mid-shift top-ups, is still developing. The diverse usage patterns of mid-size vans—from last-mile delivery to service trades—also mean a one-size-fits-all solution is difficult to engineer. Automakers are likely prioritizing segments with clearer demand and more straightforward technical solutions, leaving the more complex mid-size market for a later phase of electrification.
As battery energy density improves and costs decrease, this gap in the market is expected to close. However, for now, the mid-size electric van represents a formidable engineering and economic challenge that the industry is still working to solve.