While battery electric vehicles (BEVs) are pivotal for transport decarbonization, existing life cycle assessments (LCAs) often confound vehicle design effects with inter-brand manufacturing variations. In this study, a comparative cradle-to-grave LCA was conducted for three distinct BEV segments—a sedan, an SUV, and an MPV, produced by a single manufacturer on a shared platform. Leveraging detailed bills of materials, plant-level energy data, and region-specific emission factors for a functional unit of 150,000 km, we quantify greenhouse gas emissions across the full life cycle. Results show the total emissions scale with vehicle size from 25 to 31 t CO2-eq. However, the MPV exhibits the highest functional carbon efficiency, with the lowest emissions per unit of interior volume. Material production and operational electricity use dominate the emission profile, with end-of-life metal recycling providing a 15–20% mitigation credit. Scenario modeling reveals that grid decarbonization can slash life cycle emissions by around 30%, while advanced battery recycling offers a further 15–18% reduction. These findings highlight that the climate benefits of BEVs are closely linked to progress in power system decarbonization, and provide references for future optimization of low-carbon vehicle production and reuse.
Zhu et al. (Tue,) studied this question.