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Cold Weather Cracks EV Range: U.S. Industry Responds

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  Published in Automotive and Transportation on Saturday, November 29th 2025 at 4:19 GMT by Business Insider

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How the U.S. Auto Industry is Tackling the Cold: A Deep Dive into EV Winter Performance and the Latest Moves by Tesla, Ford, and GM

When people think about electric vehicles (EVs) they rarely consider the way a drop in temperature can bite into a battery’s range. A Business Insider feature published in late November 2025 pulls back the curtain on the cold‑weather challenges that have rattled the U.S. auto industry and explores how the biggest players—Tesla, Ford, and General Motors—are engineering solutions, tweaking strategies, and reshaping their product line‑ups to keep the electric dream alive even when the mercury drops.

1. The Winter‑Range Problem: Numbers and Science

The article opens with a stark statistic: in temperatures below 30 °F, a typical EV’s range can shrink by 20–30 %. The drop is largely due to two things:

1. Battery chemistry – Lithium‑ion cells are less efficient in the cold; internal resistance rises, and the energy density drops.
2. Heat‑management systems – Most EVs rely on battery‑heater power drawn from the grid or the vehicle’s battery itself, effectively shaving energy from the driving range.

Tesla’s data are front‑and‑center. According to the piece, Model 3 drivers in Seattle report an average 22 % drop in range from the advertised 263 mi at 70 °F to 206 mi at 20 °F. Yet Tesla’s 2026 battery pack, unveiled in a 2025 investor presentation, promises a 15–20 % improvement in cold‑weather efficiency thanks to a new 2170‑cell chemistry that stays warmer for longer and a revamped heat‑management algorithm.

Ford and GM, the article notes, are following suit. Ford’s F‑150 Lightning, now in its third generation, incorporates a “thermal buffer” – a phase‑change material that keeps the cells within a narrow temperature band during charge and discharge cycles, reducing the need for active heating. GM’s Chevy Bolt EUV, meanwhile, relies on a smaller, more densely packed battery that can warm up faster, trading some total capacity for improved cold‑weather performance.

2. Tesla’s Strategic Moves

Tesla is not only pushing for better battery chemistry; the article also highlights a broader shift in the company’s manufacturing and logistics. In a 2024 production update, Tesla moved its “Megapack” assembly plant to a climate‑controlled location in Austin, Texas, to sidestep the supply‑chain bottlenecks that had plagued its earlier battery production. This decision, Business Insider reports, has cut the average cold‑weather battery production time by 30 %, enabling faster deployment of the new 2026 packs.

Tesla also doubled down on its “Vehicle‑to‑Grid” (V2G) testing. By allowing the car to feed power back into the grid during peak demand, the company can use the battery’s stored heat for grid services, thereby offsetting the energy cost of heating. The article quotes Tesla’s Head of Energy Services, who says “V2G is our answer to the winter range problem because it lets us monetise battery temperature while we’re not driving.”

3. Ford’s “Smart Heat” Initiative

Ford’s approach is very different. The Business Insider piece describes the company’s “Smart Heat” initiative, which incorporates a 48‑V “auxiliary battery” that powers a high‑efficiency heat‑pump rather than a resistive heater. The system, described as “almost as good as a car heater,” maintains cabin comfort while drawing only a fraction of the power that traditional systems use.

Ford’s marketing team, the article reports, has also been re‑framing the winter range narrative. Instead of focusing on raw numbers, they are promoting “Winter‑Ready” as a new product feature, supported by a series of short videos featuring drivers in snowy Midwest towns. According to the piece, early market feedback shows a 12 % uptick in test‑drive traffic for vehicles equipped with Smart Heat versus conventional heating systems.

4. GM’s “Ultra‑Compact” Battery Pack

General Motors is banking on battery size reduction and efficiency. GM’s new “Ultra‑Compact” battery pack uses a 26650‑cell chemistry that is smaller, lighter, and more thermally stable than the 2170 cells used by Tesla. Business Insider’s analysis indicates that the pack can be charged 40 % faster at a 150‑kW charger, while still achieving 4–5 % better range in cold climates.

The article also delves into GM’s supply‑chain strategy. GM has signed long‑term contracts with lithium‑minerals companies in the Nevada and Arizona deserts, allowing the automaker to secure a steadier supply of raw materials that is less susceptible to weather‑related disruptions.

5. A Broader Picture: Regulatory and Consumer Implications

Beyond the corporate tactics, the article contextualises the issue within the broader regulatory and consumer environment. New U.S. federal standards now require automakers to disclose “range‑reduction factors” under varying temperature scenarios. The piece quotes consumer advocacy groups that are pressing for a standardized reporting system so buyers can compare vehicles on a level playing field.

The article also touches on how the winter problem influences the second‑hand market. EV resale values have dipped by 6–8 % in the past year in colder states, primarily due to concerns about battery longevity and range in winter. Business Insider’s data shows that the Tesla Model 3’s resale depreciation is less severe than the Ford F‑150 Lightning’s, largely because of Tesla’s battery management reputation.

6. The Road Ahead: Emerging Technologies and Market Dynamics

The Business Insider article concludes with a forward‑looking section that speculates on future solutions. Among them are:

• Solid‑state batteries – The industry sees this as the next big leap, though production remains expensive.
• Regenerative heating systems – Where heat is captured from braking and stored for cabin use, minimizing the need for active heating.
• AI‑driven climate control – Systems that predict temperature changes and pre‑warm or pre‑cool the cabin efficiently.

The article also reminds readers that the EV market is still evolving. With the U.S. federal government investing $7.5 billion in EV infrastructure through the 2025 Inflation Reduction Act, manufacturers are accelerating their roll‑outs. Tesla plans to open a new Gigafactory in Georgia focused on “thermal‑efficient” batteries, Ford is launching a “Flex‑Drive” platform that could support both EVs and hybrids, and GM is investing heavily in “carbon‑neutral” battery production.

Takeaway

The Business Insider feature delivers a nuanced view of the challenges the U.S. auto industry faces in the cold‑weather testing arena. Tesla, Ford, and GM each bring a unique toolkit—from advanced battery chemistries and smart heat‑pump systems to supply‑chain realignments and AI‑powered climate control—to mitigate winter range loss. As regulations tighten and consumer expectations shift, the race is on for the next generation of EVs that can deliver the same performance in the snow as they do in the sun.