Top 5 BEV manufacturers by battery capacity deployed and average battery size

Over the first eight months of 2025, 648.5 GWh of battery capacity was deployed onto roads globally in all newly sold passenger EVs combined, 28% more than the same period last year.

Full electric vehicles (BEVs) accounted for 82% of the total, or 529.0 GWh, while the share of plug-in hybrid electric vehicles (PHEVs) was 17%, at 113.2 GWh.

BEV capacity deployment registered 28% growth and PHEVs 32% year-on-year, thanks to the latter’s expanding average battery size. For the first eight months of the year, the average BEV battery size was 62.4 kWh, down 2% while PHEV packs increased by 3% to a sales weighted average of 24.2 kWh.

Among the top BEV manufacturers, sales weighted average battery capacity vary widely.

When considering BEV unit sales global number one electric vehicle maker, BYD Group, first overtook long time leader Tesla in the final quarter of 2023 and now enjoys a healthy lead over its US rival.  

Taking into account BEV battery capacity deployed however, BYD only surpassed Tesla in the second quarter of this year due to the Shenzhen-based company’s noticeably smaller average packs fitted to its BEVs.  

From January through August 2025 the combined battery capacity deployed in BEVs made by BYD, including its offshoot brands Denza and Fang Cheng Bao, totaled 75.0 GWh, a 27% jump over the same months last year.

The average battery size of the company’s BEVs came in at 56.1 kWh, well below the global average given the overrepresentation of small, budget BEVs in its line-up.   

Tesla, which is having a difficult 2025 so far, saw battery capacity deployment shrink by 11% over the period to 71.5 GWh at an average size of 72.1 kWh across the Cybertruck and its S,3,X and Y model range.

Third placed Geely, the sprawling Chinese auto group that includes the Volvo, Polestar, Zeekr and Geometry brands among others, saw the average battery size of its full electric vehicles drop significantly this year.   

Geely has moved 83% more BEVs year to date, but in GWh terms the company based in the city of Hangzhou, expanded at a much slower rate of 49% for a total of 48.5 GWh.

The sales weighted average battery capacity of BEVs in the Geely stable is the lowest among the top EV makers at 54.1 kWh.

A third of Geely’s unit sales so far this year was in the form of the new Xingyuan, which retails for under $10,000 and sports a battery pack of just over 30 kWh. The urban runabout, available only in China, is now the second most sold BEV worldwide, and is largely responsible of the big drop in the company’s average battery size.

In fourth place, just a car length behind Geely, is Volkswagen, which, after 48% year-on-year growth, saw the German group deploy 48.4 GWh of total BEV battery capacity.

Among the top five, Volkswagen’s average battery capacity is the highest at 77.9 kWh. Wolfsburg’s upmarket and sporty Audi and Porsche brands, which make up nearly 30% of the company’s shipments, can take some of the credit for the above average pack capacity.   

Some distance behind its German rival, the Hyundai Motor Group rounds out the top five with 23.7 GWh deployed, a 23% increase over the January-August period in 2024 at an average capacity of 69.4 kWh.

A third of the Korean carmakers sales so far this year have been BEVs, the lowest share among the top 5. Hyundai-badged vehicles make up 51% of the group’s sales and the Kia brand 45%. Its Genesis luxury label and a joint venture in China split the remainder.

Further down the GWh deployed rankings there are a few outliers, notably General Motors (position number 9) with an average BEV battery size of 109.7 kWh, beefed up by the GMC Hummer, the Chevrolet Silverado pickup, and its upscale Cadillac marque.

SGMW occupies the opposite end of the spectrum with an average battery size of a humble 24.0 kWh. While number five in terms of sales, its overreliance on the Hongguang Mini EV (nearly half its overall sales), sees it only reach the 14^th spot this year when it comes to total GWh deployed in full electric vehicles.   

Contact the Adamas team to learn more or check out the intelligence services below.