Top 5 plug-in hybrid EV producing countries and average battery size
BEV battery capacity deployment growth surpassed that of PHEVs in January for the first time since 2022 and exceeded it for five of the last eight months.
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, after expanding by 28% year on year. The share of plug-in hybrid electric vehicles (PHEVs) was 17% at 113.2 GWh, recording growth of 32% so far this year.
Since 2002, BEV global battery capacity deployment growth has lagged that of PHEVs. The latter started from a lower base and often expanded at more than double the rate, but now that trend is beginning to reverse.
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. The trend of bigger and bigger batteries for both BEVs and PHEVs, a feature of the market since at least 2022, is also leveling off.
China has an even stronger grip on plug-in hybrid production than the overall EV market with 3.6 million PHEVs made in-country constituting 76% of global sales so far this year.
A total of 92.6 GWh of PHEV battery capacity hit global roads in Chinese-made PHEVs for the first time from January through August 2025, a 32% rise over the same period last year. That gives the country’s automakers a remarkable 82% global share on a GWh basis.
The average battery pack of made-in-China PHEVs are the largest among countries producing this type of EV at 26 kWh per vehicle.
The popularity of range extender EVs or EREVs in China has been a key factor behind the country’s global dominance of the PHEV category. It also contributes to bulkier batteries – the sales weighted average EREV battery came in at 39.4 kWh last year, larger than most compact BEVs.
Number two PHEV producer is Germany with a less than 6% share of the global market at 6.4 GWh deployed worldwide, a 43% increase over 2024. The sales-weighted average battery size of made-in-Germany PHEVs clocked in at 20.6 kWh.
On a GWh basis, PHEVs manufactured in third-placed United States accounted for less than half that of Germany this year, at 3.1 GWh. US PHEV battery capacity deployed grew at less than 16% over the first eight months. The average battery size of PHEVs made in the US was 19.9 kWh.
PHEV battery capacity deployed in Japan fell 2% year on year to 2.7 GWh at an average of 17.4 kWh while fifth placed Spain saw its PHEV battery capacity deployment rise 22% to 1.6 GWh. The sales weighted average battery capacity of PHEVs made in Spain came to 20.7 kWh which gave the country an edge over Sweden.
Swedish PHEVs found over 15,000 more buyers this year than Spanish-made ones but at an average of only 14.6 kWh per vehicle contributed less to car parc electrification than its southern counterpart.
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