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I was invited to tour Bosch’s Charleston, South Carolina, facility to see firsthand the evolution of the world’s largest auto parts supplier as the industry transitions to electric vehicles.

Stepping into the facility is like entering Willy Wonka’s chocolate factory, but instead of chocolate rivers and little orange people, it’s filled with highly trained, motivated workers and next-generation technology working together in sync.

The company uses industry 4.0 production methods featuring artificial intelligence, precision lasers, robotics, and more to build precise, reliable auto parts at scale.

Bosch’s Charleston facility makes critical components for the auto industry shipping them out to nearly every major automaker, including Tesla, Ford, GM, and one of its latest customers, Rivian.

However, as the President of Bosch in North America, Mike Mansuetti, explains, the auto industry is “rapidly evolving” toward electric vehicles. The auto parts supplier is investing in a sustainable future by introducing new EV products and parts for its customers, bringing the technology to market at scale.

Mr. Manuetti says:

We’ve invested more than $6 billion dollars in electromobility development and
in 2021 our global orders for electromobility surpassed $10 billion dollars for the
first time. Local production helps to advance our customers’ regional
electrification strategies, and further supports the market demand for
electrification.

Bosch announced in January 2020 that it would begin to slow production of its diesel powertrain components to focus on sustainable solutions. A prime example of the rapidly evolving industry, the building is now being used to build electric motors for the Rivian R1T.

Bosch-electric-vehicles
Rivian R1T outside of Bosch’s Charleston facility

Bosch is building its portfolio to power electric vehicles

Bosch began production of the electric motors in October for the Rivian R1T, marking a “new era of electrification” for the global auto parts leader. The manufacturing site covers around 200,000 square feet in the previously used diesel components area.

The electric motor consists of two primary parts – the rotor and the stator. The stator features winded copper bars for superior efficiency and power density. The coils receive energy from alternating current coming via power electronics from the battery.

Meanwhile, the rotor is filled with magnets by the process of transfer molding to promote fewer air pockets. As the current flows into the stator, the rotor’s magnetic field chases that of the stator, generating energy that powers the vehicle’s wheels. The casing then consists of an aluminum A-shed and B-shed that enclose the unit.

The company utilizes high-tech AI-powered machinery and other robotics to reduce its carbon footprint while producing faster, more accurate results.

According to Bosch, its electric motor features 98% efficiency. In addition, the process is scalable, allowing more freedom to customers, delivering anywhere from 50 kW up to 500 kW with a torque range from 150 Nm to 1000 Nm and up to 680 HP.

Bosch-Charleston-electric-vehicles-5

Since electric vehicle motors differ in size, scope, and material, the new production process came with challenges. Perhaps, more importantly, the shift to electric vehicles is creating a gap in workers to fill these high-tech manufacturing jobs.

Realizing this, Bosch is providing reskilling and upskilling opportunities for its employees while partnering with local schools to ensure there is the talent needed to propel the future of the auto industry.

Investing in electromobility training

As Bosch explained, the transition would not be possible without the workers. To accelerate the process, employees were sent to Bosch’s plants in Germany for training and to learn how they could make the manufacturing process more efficient with automation.

As a result, these are not your typical manufacturing jobs. These are high-tech jobs that involve skills such as software programming and working with automated machines.

If you think about it, when you bring your car in for a checkup, it’s not a toolbox the mechanic brings out anymore. It’s often a laptop designed to pinpoint the issue automatically. Electric vehicles are more sophisticated and therefore require a different skill set to work on.

Vehicle suppliers play an integral role in the US economy, contributing to around 2.5% of GDP. As electric vehicles continue gaining momentum, surpassing gas-powered vehicle sales, the workforce will need to be able to support the transition.

Bosch’s $260 million expansion is expected to create 350 net new jobs by 2025, and this is just the start. To position itself for the future in the auto industry, Bosch is partnering with local schools in Charleston, such as Trident Technical College, to integrate electric vehicle education into the curriculum.

The auto supplier’s corporate foundation, The Bosch Community Fund, has provided $2.5 million in STEM education efforts in the Charleston area since 2013.

Electrek’s Take

With electric vehicles on track to claim 13% of global new car sales in 2022, the rapidly evolving auto industry is establishing a new stream of jobs. What Bosch is doing is taking employees that were previously working on parts for gas-powered cars and training them for the future of the industry.

However, the company is finding that there are major stigmatizations and built-in perceptions around manufacturing jobs that don’t apply anymore.

People will not be interested in what they don’t know. These manufacturing jobs utilize skills that some kids use essentially every day, like video games that require quick thinking and analytical skills.

The issue is that educators are unaware of what future manufacturing jobs will look like, thanks to the electric vehicle revolution. Teachers are not pushing for these jobs because they don’t associate them with the skills that they will be using. Same idea with parents.

To support the new EV era, what needs to happen is a change in perception that gets people interested in the auto industry’s future and putting the US back on track to become a manufacturing powerhouse.

Last year, new electric vehicle jobs soared 26.2%, establishing 21,961 new positions. And this year, the pace has accelerated even further with new climate initiatives and substantial investments from foreign automakers on US soil.

Since the beginning of 2021, companies have invested around $85 billion in manufacturing operations for electric vehicles, batteries, and chargers, all of which require a new set of skilled workers.

The opportunities electric vehicles are creating in the United States are already showing, and the EV market share is just reaching 6%. Imagine what will happen in another year.

Bosch, the largest auto supplier worldwide, will play a significant role in the transformation. During my visit, they seemed eager and up to the challenge of supporting the incoming wave of electric vehicles and the future of the industry.

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Meet the newest EV from Hyundai – new HX19e electric excavator

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Meet the newest EV from Hyundai – new HX19e electric excavator

The HD arm of Hyundai has just released the first official images of the new, battery-electric HX19e mini excavator – the first ever production electric excavator from the global South Korean manufacturer.

The HX19e will be the first all-electric asset to enter series production at Hyundai Construction Equipment, with manufacturing set to begin this April.

The new HX19e will be offered with either a 32 kWh or 40 kWh li-ion battery pack – which, according to Hyundai, is nearly double the capacity offered by its nearest competitor (pretty sure that’s not correct –Ed.). The 40kWh battery allows for up to 6 hours and 40 minutes of continuous operation between charges, with a break time top-up on delivering full shift usability.

Those batteries send power to a 13 kW (17.5 hp) electric motor that drives an open-center hydraulic system. Hyundai claims the system delivers job site performance that is at least equal to, if not better than, that of its diesel-powered HX19A mini excavator.

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To that end, the Hyundai XH19e offers the same 16 kN bucket breakout force and a slightly higher 9.4 kN (just over 2100 lb-ft) dipper arm breakout force. The maximum digging depth is 7.6 feet, and the maximum digging reach is 12.9 feet. Hyundai will offer the new electric excavator with just four selectable options:

  • enclosed cab vs. open canopy
  • 32 or 40 kWh battery capacity

All HX19es will ship with a high standard specification that includes safety valves on the main boom, dipper arm, and dozer blade hydraulic cylinders, as well as two-way auxiliary hydraulic piping allows the machine to be used with a range of commercially available implements. The hydraulics needed to operate a quick coupler, LED booms lights, rotating beacons, an MP3 radio with USB connectivity, and an operator’s seat with mechanical suspension are also standard.

Like its counterparts at Volvo CE, the new Hyundai excavator uses automotive-style charging ports to take advantage of existing infrastructure at fleet depots and public charging stations. More detailed specifications, dimensions, and pricing should be announced by bauma.

Electrek’s Take

HX19e electric mini excavator; via Hyundai Construction Equipment.

The ability to operate indoors, underground, or in environments like zoos and hospitals were keeping noise levels down is of critical importance to the success of an operation makes electric equipment assets like these coming from Hyundai a must-have for fleet operators and construction crews that hope to remain competitive in the face of ever-increasing noise regulations. The fact that these are cleaner, safer, and cheaper to operate is just icing on that cake.

SOURCE | IMAGES: HD Hyundai; via Construction Index, Equipment World.

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Harbinger guarantees incentive pricing to combat Trump Administration chaos

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Harbinger guarantees incentive pricing to combat Trump Administration chaos

With the Trump Administration fully in power and Federal electric vehicle incentives apparently on the chopping block, many fleet buyers are second-guessing the push to electrify their fleets. To help ease their minds, Harbinger is launching the IRA Risk-Free Guarantee, promising to cover the cost of anticipated IRA credits if the rebate goes away.

The‬‭ Inflation Reduction Act‬‭ (IRA) 45W Commercial Clean Vehicle‬ Credit‬‭ offers up to $40,000 per medium-duty commercial EV. Originally proposaed as part of President Biden’s Green New Deal package, the incentive‬‭ was put in place to help modernize commercial fleets by overcoming obstacles like the higher up-front costs of EVs.

In the case of a Harbinger S524 Class 5 chassis with a 140 kWh battery capacity with an MSRP of $103,200, the company will offer an IRA Risk-Free Guarantee credit of $12,900 at the time of purchase, bringing initial cost down to $90,300. This matches the typical selling price of an equivalent Freightliner MT-45 diesel medium-duty chassis.

“We created (the IRA Risk-Free Guarantee) program to eliminate the financial uncertainty for customers who are interested in EV adoption, but are concerned about the future of the IRA tax credit,” said John Harris, Co-founder and CEO of Harbinger. “For electric vehicles to go mainstream, they must be cost-competitive with diesel vehicles. While the IRA tax credit helps bridge that gap, we remain committed to price parity with diesel, even if the credit disappears. Our vertically integrated approach enables us to keep costs low, shields us from tariff volatility, and ensures long-term‭ price stability for our customers.”

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Harbinger‬‭ recently revealed a book of business consisting of 4,690 binding orders. Those orders are valued at approximately $500 million, and fueled a $100 million Series B raise.

Electrek’s Take

Harbinger truck charging; via Harbinger.

One of the most frequent criticisms of electric vehicle incentives is that they encourage manufacturers and dealers to artificially inflate the price of their vehicles. In their heads, I imagine the scenario goes something like this:

  • you looked at a used Nissan LEAF on a dealer’s lot priced at $14,995
  • a new bill passes and the state issues a $2500 used EV rebate
  • you decide to go back to the dealer and buy the car
  • once you arrive, you find that the price is now $16,995

While it’s commendable that Harbinger is taking action and sacrificing some of its profits to keep the business growing and the overall cause of fleet electrification moving forward, one has to wonder how they can “suddenly” afford to offer these massive discounts in lieu of government incentives – and how many other EV brands could probably afford to do the same.

SOURCE | IMAGES: Harbinger.

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It just gets worse for Nikola as massive hydrogen recall follows bankruptcy

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It just gets worse for Nikola as massive hydrogen recall follows bankruptcy

Whoever is left at Nikola after the fledgling truck-maker filed for Chapter 11 bankruptcy protection last month is probably having a worse week than you – the company issued a recall with the NHTSA for 95 of its hydrogen fuel cell-powered semi trucks.

Nikola filed for Chapter 11 protections just a few weeks after we predicted the company would go “belly up,” reporting that the company was planning to halt production of its hydrogen fuel cell-powered semi trucks while, at the same time, Nikola’s stock had sunk to a 52-week low following a formal NHTSA complaint claiming the fuel cell shuts down unpredictably.

That complaint seems to have led to the posthumous recall of 95 (out of about 200) Nikola-built electric semi trucks.

The latest HFCEV recall is on top of the 2023 battery recall that impacted nearly all of Nikola’s deployed BEV fleet. Clean Trucking is citing a January 31, 2025 report from the NHTSA revealing that, as of the end of 2024, Nikola had yet to complete repairs for 98 of its affected BEVs. The ultimate fate of those vehicles remains unclear.

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Electrek’s Take

Nikola Coyote Container completes historic trip in fuel cell truck
Image via Coyote Container.

I’ve received a few messages complaining that I “haven’t covered” the Nikola bankruptcy – which is bananas, since I reported that it was coming five weeks before it happened and there was no “new” information presented in the interim (he said, defensively).

Still, it’s worth looking back on Nikola’s headlong dive into the empty swimming pool of hydrogen, and remind ourselves that even its most enthusiastic early adopters were suffering.

“The truck costs five to ten times that of a standard Class 8 drayage [truck],” explained William Hall, Managing Member and Founder of Coyote Container. “On top of that, you pay five to ten times the Federal Excise Tax (FET) and local sales tax, [which comes to] roughly 22%. If you add the 10% reserve not covered by any voucher program, you are at 32%. Thirty-two percent of $500,000 is $160,000 for the trucker to somehow pay [out of pocket].”

After several failures that left his Nikola trucks stranded on the side of the road, the first such incident happening with just 900 miles on the truck’s odometer, a NHTSA complaint was filed. It’s not clear if it was Hall’s complaint, but the complaint seems to address his concerns, below.

NHTSA ID Nu. 11621826

Screencap; via NHTSA.

Optionally, you could just read Hall’s summary of the Nikola situation, in his own words: “I have dealt with more tow trucks in the last 10 months than in my entire 62 years on this Earth.”

The company issued a technical service bulletin (TSB) on October 29th, just 13 days after the official NHTSA complaint was filed.

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