The future of electric vehicle (EV) production is shining brightly, according to the third edition of ABB Robotics’ Automotive Manufacturing Outlook Survey, conducted in partnership with Automotive Manufacturing Solutions. This year’s survey reveals an optimistic outlook for the EV industry, with 75% of automotive manufacturing leaders forecasting an increase in EV production in 2025. However, despite the promising numbers, there is a growing sense of doubt over whether the automotive industry will meet the ambitious deadlines set for a fully electric future.
EV Growth in 2025: An Optimistic Forecast
The automotive manufacturing professionals surveyed are upbeat about the prospects for EV production in 2025. Of those surveyed, 31% predict an increase in output of over 10%, while 44% expect a more modest growth of up to 10%. With only 21% of respondents forecasting that production would either remain static (8%) or decline (13%), there is clearly a consensus that EV production will continue to rise.
Joerg Reger, Managing Director of ABB’s Automotive Business Line, underscores the optimism surrounding EV production. “This year’s survey found that overall, automotive manufacturing professionals are optimistic about EV production growth in 2025, but unsure about reaching 100 percent electric vehicle production timetables due to factors often beyond the factory environment,” he comments.
The improvements in EV manufacturing capabilities are also evident, with increased investments in new production technology and workforce upskilling. ABB Robotics, for instance, has made significant updates to its robotic and automation portfolio, aiming to support the rapid transformation of the industry. This technological evolution, coupled with a shift in workforce capabilities, suggests that the foundations for increased EV production are being laid.
Challenges Loom Over Meeting Full EV Production Deadlines
While growth in EV output seems inevitable, there is an increasing sense of uncertainty about meeting the proposed regional deadlines for 100% electric vehicle production by 2030-2040. The number of manufacturing professionals who believe this target is unattainable has risen steadily from 18% in 2022 to 31% in 2024. This increase in skepticism reflects broader concerns about the pace of transition, with 65% of respondents indicating that full EV production within the set timeframe is unlikely.
The main barriers to achieving full EV production are no longer seen as purely factory-related but are increasingly tied to external factors. Consumer demand and confidence in the availability and reliability of charging infrastructure have been highlighted as significant hurdles. As manufacturers work to ramp up production, these challenges outside the factory are emerging as critical concerns.
A Strong Future for Hybrid Powertrains
Interestingly, while the industry aims for full EV adoption, hybrid vehicles—particularly plug-in hybrid electric vehicles (PHEVs) and hybrid electric vehicles (HEVs)—are poised for strong growth in 2025. According to the survey, 67% of respondents expect PHEV production to increase, with 20% predicting growth of over 10%. Similarly, 62% of manufacturing experts forecast that HEV production will see a boost this year.
Hybrid powertrains remain an important bridge in the transition toward full electrification, offering a practical solution for markets still grappling with charging infrastructure and consumer adoption. Daniel Harrison, Chief Analyst for Automotive Manufacturing Solutions, points out that the persistence of hybrid vehicle production indicates that the shift to EVs is not progressing quickly enough to meet upcoming legislative deadlines. “Hybrid passenger vehicle production remains buoyant with the global manufacturing community expecting to produce more cars in 2025. These results support the survey’s main findings that the overall pace of EV adoption is currently not fast enough to reach some of the upcoming legislative deadlines for a 100% electric future,” says Harrison.
Navigating Complexity and Cost
As manufacturers expand their portfolios to include a diverse range of powertrains, complexity and cost are becoming increasing concerns. The ability to produce multiple powertrain variants across different models adds layers of complexity to the production process, resulting in higher costs. This complexity, noted in previous surveys conducted by ABB Robotics, presents a challenge for manufacturers seeking to scale up EV production while managing expenses.
The survey underscores the need for greater clarity and consistency in regulations and incentives to support the transition to electric mobility. As the global automotive industry navigates this complex landscape, the continued growth of hybrid powertrains may serve as a vital part of the solution in the short to medium term.
Looking Ahead
The 2025 outlook for EV production is undoubtedly positive, but challenges remain. While manufacturing leaders are optimistic about increased EV output, the uncertainties surrounding the transition to full electric vehicle production by 2030-2040 are significant. As the industry focuses on overcoming external barriers such as charging infrastructure and consumer confidence, the role of hybrid vehicles in meeting immediate needs cannot be overstated.
Ultimately, achieving a fully electric future will require continued innovation, strategic collaboration, and the flexibility to adapt to a rapidly evolving landscape. The next few years will be crucial in determining whether the automotive industry can meet its ambitious targets, and whether new technologies and consumer behavior will align to make the vision of a 100% electric vehicle market a reality.
