Why Most Commercial EV Charging Projects Cost More Than Expected

And how to design a system that actually works in the real world

Commercial EV charging is often treated as a hardware purchase. In reality, it is an infrastructure design problem.

Stop Thinking About Charger Price

Every commercial EV charging project has three cost layers:

• Equipment: Chargers and hardware
• Infrastructure: Electrical upgrades, trenching, installation
• Operations: Energy, maintenance, uptime

Focusing only on hardware leads to poor decisions and higher total cost.

The Biggest Mistake: Overbuilding Power

Many projects default to 150–350 kW chargers. This often creates:

• Unnecessary electrical upgrades
• Higher install costs
• Longer timelines
• Fewer viable deployment locations

Reality Check

Most EVs today are limited to ~150–160 kW charging. Anything beyond that is often wasted.

The Better Approach: Right-Sized DC Fast Charging

Splitvolt systems are designed for real-world applications—not spec sheets.

• 40–160 kW optimized charging range
• Full power available per connector (not split limited)
• Compact, lightweight systems
• Flexible installation (wall, pedestal, mobile)

Why Right-Sized Systems Win

Lower Total Project Cost

Avoid expensive infrastructure upgrades and reduce install complexity.

More Deployable Locations

Fit into parking garages, urban spaces, and constrained environments.

Faster Deployment

Less engineering complexity = faster time to revenue.

Better Real-World Performance

Optimized for fleet, workplace, and destination charging.

Physical Design Matters

• Typical 150kW systems: 350–550 kg, large footprint
• Splitvolt S-80 Duo: ~220 kg, compact design

This impacts:

• Transport costs
• Installation difficulty
• Site flexibility

Hybrid AC + DC: The Smartest Strategy

Most successful deployments combine:

• DC Fast Charging: High throughput where needed
• AC Wall Stations: Low-cost expansion across many stalls

This approach delivers:

• Lower cost per charging port
• Higher total site capacity
• Better ROI

Design for Real-World Success

The most effective EV charging deployments focus on:

• Right-sized power levels
• Infrastructure efficiency
• System-level design
• Scalability and flexibility

Conclusion

The best EV charging systems are not the most powerful—they are the most deployable, efficient, and aligned with real-world use.