The Importance of Reliable Charging Station Electronics for Building a Sustainable EV Ecosystem

The rapid transition to electric vehicles (EVs) demands a robust and reliable charging infrastructure to support user confidence and safety. This paper explores how the reliability of EV charging station electronics is foundational to the broader sustainability of the EV ecosystem. Drawing parallels from high-reliability industries such as automotive and
aerospace, the paper introduces the “Connect – Clean – Coat” methodology as a practical framework for ensuring durable and high-performing electronics in harsh outdoor environments. It outlines challenges facing Level 3 chargers—including high-voltage operation, thermal extremes, humidity, and contamination—and emphasizes how failure in these systems leads to high maintenance costs, lost revenue, and negative user experiences.

The paper also highlights industry collaboration efforts led by the Global Electronics Association's e-Mobility Quality and Reliability Advisory Group and introduces proven reliability testing methods such as HALT and HASS to uncover design and process vulnerabilities. By adopting best practices and harmonized standards, manufacturers can reduce total cost of ownership (TCO), minimize environmental impact, and build consumer trust on the path to achieving zero-failure charging infrastructure. Reliability, the new “R” in sustainability, is essential for the successful scaling of electric mobility infrastructure.