Nikola had major defect in its Romeo battery, may have caused truck fire
Nikola Corporation had a significant safety defect in the battery modules used in its electric semi trucks that can result in fires. Yet, the company was quick to claim “foul play” when five trucks caught on fire at its headquarters last week.
Nikola says that it is still investigating the situation.
Last week, we reported on the Phoenix fire department confirming that five Nikola semitrucks caught on fire at their headquarters. The company was quick to tell the public it believed “foul play” was involved in the fire, but it didn’t have a lot of evidence to back the claim. It only mentioned that a vehicle was seen on the scene prior to the fire.
The Phoenix fire department was still investigating the fire at the time Nikola made that statement. We contacted the fire department to ask for an update on the investigation when it is available, but we haven’t received an update yet.
In the meantime, we received concerning information about the battery modules that Nikola uses in its electric trucks, which company insiders believe could have led to the fire.
Nikola gets its battery modules for its Tre semitruck from Romeo Power, a company that it acquired last year after already being its main client for battery pack design and manufacturing. Romeo designed and produced the Hermes and Legion battery modules for the Nikola Tre.
Last year, engineers working on the battery modules detected a major problem where the cells were corroded and would self-discharge.
Electrek saw an internal report that investigated the issue:
A team inspected a number of modules in production, and many had the same issue.
They eventually tracked the problem down to the laser welding puncturing some of the battery cells in the modules.
The tests in the report were performed on the Hermes module because, unlike the Legion module, it doesn’t have potting on the cells, which can hide the puncture issue, but the problem was first identified in the Legion module, which is the one that was delivered to Nikola during the time it started production of the Tre, according to a source familiar with the matter.
Electrek was shown a video of the problem with the cells corroding within only two cycles in some cases:
The corrosion can create heat generation and increase resistance at the joint.
It can create several problems, including lithium plating and an imbalance in the voltage delta, which was mentioned in Romeo Power’s report on the issue:
These issues could all lead to potential thermal events in the battery packs, according to the insider, especially as they continue to cycle.
According to a former Romeo employee with knowledge of the problem, engineering executives recommended shutting down the production of the modules, but Susan Brennan, who was CEO of Romeo at the time, decided to keep production going and to try to fix the issue in parallel.
Electrek reached out to Brennan for an interview, but we didn’t get a response.
Nikola’s leadership was also made aware of the issue, but they already had millions of dollars worth of battery modules meant for its electric semitrucks, which the company was in a hurry to bring to production as it was hemorrhaging cash.
On top of it, the relationship of buyer-supplier between Romeo and Nikola was blurred now that the latter was acquiring the former.
A company insider told Electrek that Romeo kept producing potentially damaged battery modules for Nikola, and it is possible some of those battery modules could have made it into Nikola trucks.
While we can’t confirm that it led to the trucks catching on fire at its headquarters last week, it is a possibility, as punctured cells can lead to thermal events in batteries.
We contacted Nikola about this issue, and the company acknowledged that they were aware of the problem, but they believe no damaged modules have made their way into Nikola production trucks.
A spokesperson wrote in an email:
For production Nikola vehicles, Nikola requested Romeo not to ship known leaking modules. When weld issues were identified at Romeo’s end-of-line process, a quarantine process was implemented which required performance of a thorough inspection on every module, including end-of-line functionality checks. To our knowledge and based upon assurances made by our supplier Romeo, Nikola did not put any modules with weld issues in our production vehicles.
They claim to know that based on “assurances made by [their] supplier Romeo.” Romeo is now owned by Nikola, and we have seen evidence that the problem was ongoing when Nikola was producing the Tre. A company insider disputed that there was “a quarantine process.”
Also, it’s hard to confirm which modules have punctured cells, as the Legion module has potting hiding the joints of the cells.
A Nikola spokesperson tried to convince Electrek that the problem was only with the Hermes module while the Legion module was the one that ended up in the Tre, but a source familiar with both modules told Electrek that the cell puncture issue was first identified on a Legion module at Romeo Power’s Vernon facility. It was also identified in the production modules at the Cypress facility later on.
On top of the known battery problem, a company insider told Electrek that Nikola’s claim of “foul play” was a stretch. We were shown reports and videos of fire resistance testing showing the battery modules surviving extended exposure to powerful flames:
A company insider familiar with the battery modules told Electrek that “you could literally throw burning fuel on these packs and unless it’s sustained for a long period of time, you wouldn’t even notice.” Therefore, the insider finds it hard to believe that someone was able to light the trucks on fire – leading to battery pack fires.
Obviously, the situation looks better for Nikola if someone had set the trucks on fire rather than the fire potentially originating from the batteries.
When asked by Electrek if the company is still considering “foul play,” Nikola said that it is “not ruling out anything” and it is running “multiple investigations” that “could take weeks.”
The fire comes at a difficult time for Nikola. The company has only a few weeks left to convince its shareholders to let them issue more shares in order to raise more cash to keep the company going.
Issuing more shares would further dilute Nikola’s stock, which is already down almost 94% over the last two years.
Electrek’s Take
Obviously, we need an independent investigation into this issue by experts, but it is not a good look.
As for the foul play claim, I feel like we would already have clear information on this if it were true. I doubt that Nikola wouldn’t have cameras pointed at what was millions of dollars worth of brand-new electric trucks. If there had been any foul play, it would have been identified and made public by now.
On the other side, I saw clear evidence that Nikola had a major defect in its battery modules and solid insider sources that say those modules were shipped to Nikola with no clear evidence that the problem was ever fully solved before it produced the Tre truck.
The question seems to be if Nikola really understood the situation or not and the risk that came with using the modules amid the acquisition of Romeo, but it’s not a good look either way.
Normally, I’d find it hard to believe that a company would knowingly take the risk of putting those modules inside its vehicles, but it’s not impossible, considering the company was under tremendous pressure to deliver the truck.
Nikola has been working hard to distance itself from the era of Trevor Milton, its founder, and all the fraud that happened at the time, but I certainly wouldn’t be surprised to see them cut corners again. But it sounds like there’s also the potential that Nikola thought that the Legion modules were fine when they put them in their trucks.
And before all the NKLA investors jump on me for this report, no, I don’t have and never had a short position on Nikola. I would love for Nikola’s electric truck program to be successful, as I think removing emissions from trucking is an extremely important mission.
With that said, it needs to be made safely and sustainably. That doesn’t seem to be the case with Nikola right now.
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Environment
EcoFlow members can save up to 65% on power stations while supporting disaster relief during the 2025 Member’s Festival
Portable power station specialist EcoFlow is kicking off its third annual Member’s Festival this month and is offering a unique new rewards program to those who become EcoFlow members. The 2025 EcoFlow Member’s Festival will offer savings of up to 65% for its participating customers, and a portion of those funds will be allocated toward rescue power solutions for communities around the globe through the company’s “Power for All” fund.
EcoFlow remains one of the industry leaders in portable power solutions and continues to trek forward in its vision to power a new tech-driven, eco-conscious future. Per its website:
Our mission from day one is to provide smart and eco-friendly energy solutions for individuals, families, and society at large. We are, were, and will continue to be a reliable and trusted energy companion for users around the world.
To achieve such goals, EcoFlow has continued to expand its portfolio of sustainable energy solutions to its community members, including portable power stations, solar generators, and mountable solar panels. While EcoFlow is doing plenty to support its growing customer base, it has expanded its reach by giving back to disaster-affected communities by helping bolster global disaster response efforts the best way it knows how– with portable power solutions.
EcoFlow and its members look to provide “Power for All”
Since 2023, EcoFlow has collaborated with organizations worldwide as part of its “Power for All” mission. This initiative aims to ensure access to reliable and timely power to disaster-affected communities across the globe, including rescue agencies, affected hospitals, and shelters, to support rescue and recovery efforts.
This fund most recently provided aid for communities affected by the recent Los Angeles wildfires, assistance to the Special Forces Charitable Trust (SFCT) in North Carolina following severe hurricanes, and support for non-profits engaged in hurricane preparedness in Florida and the Gulf Coast. Per Jodi Burns, CEO of the Special Forces Charitable Trust:
In the wake of devastating storms in Western North Carolina, reliable power was a critical need for the families we serve. Thanks to EcoFlow’s generous donation of generators, we were able to provide immediate relief, ensuring these families and their communities had access to power when they needed it most. We are so impressed with EcoFlow’s commitment to disaster response through their ‘Power for All’ program. It has made a tangible impact, and we are deeply grateful for their support and partnership in helping these families recover and rebuild.
In 2024, the US experienced 27 weather and climate events, each causing losses exceeding $1 billion, marking the second-highest annual total on record, according to National Centers for Environmental Information. The increasing frequency and severity of natural disasters underscore the critical need for reliable and timely power solutions during emergencies, much like EcoFlow and its members are helping provide through the “Power For All” initiative.
To support new and existing EcoFlow members, the company is celebrating its third annual Member’s Festival throughout April to offer a do-not-miss discount on its products and donate a portion of all sales to the “Power for All” fund to provide rescue power to those in need in the future. Learn how it all works below.
Save big and give back during the 2025 Member’s Festival
As of April 1st, you can now sign up to become an EcoFlow member to participate in the company’s exclusive 2025 Member Festival.
As a member, you can earn “EcoFlow Power Points” by completing tasks like registration, referrals, and product purchases and tracking your individual efforts toward disaster preparedness and recovery.
Beginning April 4, EcoFlow members will also be able to take advantage of exclusive discounts of up to 65% off select portable power stations, including the DELTA Pro Ultra, DELTA Pro 3, DELTA 2 Max, DELTA 3 Plus, RIVER 3 Plus, and more. However, these sale prices only last through April 25, so you’ll want to move quickly!
Click here to learn more about EcoFlow’s “Power for All” campaign. To register for EcoFlow’s 2025 Member Festival in the US, visit the EcoFlow website. To register as a member in Canada, visit here.
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Tesla is losing another top talent: its long-time head of software, David Lau, has reportedly told co-workers that he is exiting the automaker.
Tesla changed how the entire auto industry looks at software.
Before Tesla, it was an afterthought; user interfaces were rudimentary, and you had to go to a dealership to get a software update on your systems.
When Tesla launched the Model S in 2012, it all changed. Your car would get better through software updates like your phone, the large center display was responsive with a UI that actually made sense and was closer to an iPad experience than a car.
Tesla also integrated its software into its retail experience, service, and manufacturing.
David Lau deserves a lot of the credit for that.
He joined Tesla in 2012 as a senior manager of firmware engineering and quickly rose through the ranks. By 2014, he was promoted to director of firmware engineering and system integration, and in 2017, he became Vice President of software.
Lau listed the responsibilities of his team on his LinkedIn:
- Vehicle Software:
- Firmware for the powertrain, traction/stability control, HV electronics, battery management, and body control systems
- UI software and underlying Embedded Linux platforms
- Navigation and routing
- iOS and Android Mobile apps
- Distributed Systems:
- Server-side software and infrastructure that provides telemetry, diagnostics, over-the-air updates, and configuration/lifecycle management
- Data engineering and analytics platforms that power technical and business insights for an increasingly diverse set of customers across the company
- Diagnostic tools and fleet management, Manufacturing and Automation:
- Automation controls (PLC, robot)
- Server-side manufacturing execution systems that power all of Tesla’s production operations
- Product Security and Red Team for software, services, and systems across Tesla
Bloomberg reported today that Lau told his team he is leaving Tesla. The report didn’t include reasons for his stepping down.
Electrek’s Take
Twelve years at any company is a great run. At Tesla, it’s heroic. Congrats, David, on a great run. You undoubtedly had a significant impact on Tesla and software advancements in the broader auto industry.
He is another significant loss for Tesla, which has been losing a lot of top talent following a big wave of layoffs around this time last year.
I wonder who will take over. Michael Rizkalla, senior director of software engineering and vehicle firmware, is one of the most senior software engineers after Lau. He has been at Tesla for 7 years, and Tesla likes to promote within rather than hire outsiders.
There are also a lot of senior software execs working on AI at Tesla. Musk has been favoring them lately and he could fold Lau’s responsibilities under them.
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Kia’s electric SUVs are taking over. The EV3 is the best-selling retail EV in the UK this year, giving Kia its strongest sales start since it arrived 34 years ago. And it’s not just in the UK. Kia just had its best first quarter globally since it started selling cars in 1962.
Kia EV3 is the best-selling EV in the UK through March
In March, Kia sold a record nearly 20,000 vehicles in the UK, making it the fourth best-selling brand. It was also the second top-seller of electrified vehicles (EVs, PHEVs, and HEVs), accounting for over 55% of sales.
The EV3 remained the best-selling retail EV in the UK last month. Including the EV6, three-row EV9, and Niro EV, electric vehicles represented 21% of Kia’s UK sales in March.
Kia said the EV3 “started with a bang” in January, darting out as the UK’s most popular EV in retail sales. Through March, Kia’s electric SUV has held on to the crown. With the EV3 rolling out, Kia sold over 7,000 electric cars through March, nearly 50% more than in Q1 2024.
The EV3 was the best-selling retail EV in the UK in the first quarter and the fourth best-selling EV overall, including commercial vehicles.
Starting at £33,005 ($42,500), Kia said it’s the “brand’s most affordable EV yet.” It’s available with two battery packs, 58.3 kWh or 81.48 kWh, good for 430 km (270 miles) and 599 km (375 miles) of WLTP range, respectively.
With new EVs on the way, this could be just the start. Kia is launching several new EVs in the UK this year, including the EV4 sedan (and hatchback) and EV5 SUV. It also confirmed that the first PV5 electric vans will be delivered to customers by the end of the year.
Electrek’s Take
Globally, Kia sold a record 772,351 vehicles in the first quarter, its best since it started selling cars in 1962. With the new EV4, the brand’s first electric sedan and hatchback, launching this year, Kia looks to build on its momentum in 2025.
Kia has also made it very clear that it wants to be a global leader in the electric van market with its new Platform Beyond Vehicle (PBV) business, starting with the PV5 later this year.
Earlier today, we learned Kia’s midsize electric SUV, the EV5, is the fourth best-selling EV in Australia through March, outselling every BYD vehicle (at least for now). The EV5 is rolling out to new markets this year, including Canada, the UK, South Korea, and Mexico. However, it will not arrive in the US.
For those in the US, there are still a few Kia EVs to look forward to. Kia is launching the EV4 globally, including in the US, later this year. Although no date has been set, Kia confirmed the EV3 is also coming. It’s expected to arrive in mid-2026.
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