Electric Delivery Vans: Meeting the Growing Demand
The electrification of the automobile industry extends beyond consumer vehicles, encompassing commercial vehicles as well. With delivery vans often traveling less than 160 miles daily—a range easily achievable by current battery technology—fleet operators and e-commerce giants are increasingly switching to electric vans. Below are some of the noteworthy options in this growing market.
Tesla Robovan
Tesla estimates the Robovan to have an incredibly low travel cost of just 5-10 cents per mile.
The Tesla Robovan represents a futuristic approach to electric van design. Its sleek, streamlined exterior draws inspiration from art deco trains of the 1920s and 30s. While it lacks conventional windscreens, it features small, window-like glass panels at the front and rear, potentially incorporating electrochromic technology for on-demand transparency.
This fully autonomous electric van is designed with trunks at both ends. Tesla plans to offer an optional solar canopy that extends on both sides, tripling the roof area, as mentioned by Elon Musk on X (formerly Twitter) in 2022. The interior resembles a lounge, complete with comfortable seating, ambient lighting, a flat floor, and two large TV-sized screens—one at the front and one at the back. It is designed to accommodate up to 20 people, and Tesla is considering a commercial version for transporting goods.
The passenger version’s travel cost is expected to be between just 5-10 cents per mile. While the Robovan’s release date has yet to be announced, a 2028 launch is the earliest possibility.
USPS Electric Mail Truck
Oshkosh Defense developed the Next Generation Delivery Vehicle (NGDV) for the United States Postal Service (USPS). Unlike the futuristic designs seen from new companies like BrightDrop and Rivian, the Oshkosh Corporation subsidiary’s design is, to put it mildly, unconventional. Its appearance has been likened to a duck-billed big box.
The Oshkosh NGDV prioritizes eco-friendliness and ease of use for carriers. Safety features include front and rear parking sensors, a 360-degree camera system, a blind spot warning system, an automatic electronic parking brake, and airbags. Security is enhanced by a surveillance camera, while comfort is ensured with AC and a walk-in cargo area with cab access.
The Oshkosh NGDV will be available in both internal combustion engine (ICE) and pure electric variants. Currently, no specifications, even targeted figures, have been released. Oshkosh Defense manufactures the NGDV in Spartanburg, South Carolina, and began delivering the ICE variant to USPS on May 31, 2024. USPS deployed four units of the combustion-engined variant at the Sorting and Delivery Center in Athens, Georgia, on the same day.
In August 2024, the National Association of Letter Carriers (NALC) reported that Oshkosh Defense would manufacture the first all-electric units, with USPS aiming to put them into service that month. However, further updates are pending. USPS plans to procure a minimum of 60,000 NGDVs by 2028, with at least 45,000 being electric.
Ford E-Transit
Ford started shipping the E-Transit electric van to customers from its Kansas City Assembly Plant on February 8, 2022. In the U.S., the E-Transit starts at USD 45,995, excluding a USD 1,895 destination fee. The model quickly became the best-selling electric van in the U.S. in 2022, and sales rose to 7,672 units in 2023, securing its position as the top-selling electric van for a second consecutive year.
The Ford E-Transit is the best-selling electric van in America. Demand is expected to increase further as Ford plans to improve the range, a crucial factor for potential EV buyers. On August 21, 2024, Ford confirmed plans to extend the E-Transit’s range by incorporating new cells manufactured by the BlueOval SK joint venture company’s Plant 1 in Glendale, Kentucky, as early as mid-2025.
BlueOval SK expects this factory to be ready in the first half of 2025. Keli McAlister, the director of external affairs, shared this information in an interview with The Korea Herald on July 17, 2024. The E-Transit offers six configurations (three roof heights, three lengths, and as a Cargo Van, Chassis Cab, and Cutaway). It currently uses an 89 kWh lithium-ion battery and a single permanent-magnet motor producing 198 kW (266 hp) and 317 lb.-ft. of torque. On a full charge, it can cover 159 miles in the low-roof cargo van configuration.
New Ford Electric Van
Ford also announced plans on August 21, 2024, to produce a new electric van at the Ohio Assembly Plant, commencing in 2026. Though initially speculated to be the second-generation E-Transit, this is unlikely, given the upgraded version of the current E-Transit planned for mid-2025. The 2026 electric van is expected to target a new segment, expanding Ford’s offerings in the electric van market.
Rivian EDV 900
The Rivian electric van is built on the R1’s skateboard chassis, albeit at a lower cost (using a lot of steel).
Rivian offers three versions of the EDV: the EDV 500, EDV 700, and EDV 900, which are named according to their respective load capacities. While the EDVs initially featured a dual-motor, front-wheel-drive layout borrowed from the R1T, future models will also offer a single-motor configuration.
Amazon deployed Rivian-sourced electric delivery vans in the U.S. in the summer of 2022. As of July 10, 2024, Amazon has over 15,000 units of these models in service, operating in over 1,800 cities and having delivered over 260 million packages. Amazon plans to acquire a total of 100,000 EDVs from Rivian. Rivian revised its terms and conditions with Amazon, allowing the company to sell commercial vans to other customers, according to Founder and CEO RJ Scaringe during the Q3 earnings conference call on November 7, 2023.
In an SEC filing on October 1, 2021, Rivian revealed the following specifications:
Rivian has started using an LFP (lithium iron phosphate) battery pack in the EDV, reducing costs and improving supply stability. “In the case of our commercial vans, 100% of the commercial vans are moving to LFP pack configuration,” RJ Scaringe, Founder, Chairman, and CEO of Rivian, announced during the May 9, 2022, Q1 earnings call.
Rivian Commercial Van
Following the agreement change with Amazon, Rivian released a modified version of the Electric Delivery Van (EDV) for other customers, now called the ‘Commercial Van.’ The Rivian Commercial Van includes LED headlights, a curbside sliding door, a 15.6-inch central touchscreen, two wireless charging pads, a 360-degree camera system, three airbags, automatic emergency braking, and various advanced driver assistance systems.
The Rivian Commercial Van is available in 500 and 700 versions, mirroring the Amazon EDV models. The Rivian Delivery 500 Commercial Van has a GVWR of 9,350 lbs. and a payload capacity of 2,734 lbs., with an estimated range of 161 miles per charge. The Rivian Delivery 700 Commercial Van has a higher GVWR of 9,500 lbs., offers a larger cargo area, but a lower payload capacity of 2,513 lbs. Its estimated range is slightly lower at 153 miles.
The Rivian Commercial Van is priced at USD 83,000 for the 500 version and USD 87,000 for the 700 version. Both models may qualify for a federal tax credit of up to USD 7,500. Deliveries were scheduled to begin on a limited scale in early 2024.
Chevrolet BrightDrop 400
The BrightDrop Zevo 400 and BrightDrop Zevo 600, originally known as BrightDrop 410 and BrightDrop 600, were renamed in 2024 to Chevrolet BrightDrop 400. Conceived in GM’s Innovation Lab in January 2021, BrightDrop became part of GM Envolve in November 2023. In August 2024, GM brought the electric commercial van start-up under the Chevrolet brand. All Chevrolet dealers that meet GM’s commercial EV requirements can sell BrightDrop vans, benefiting customers with wider availability.
The Chevrolet BrightDrop 400 is designed for smaller, frequent deliveries, measuring 238.6 in. in length with a 153.1 in. wheelbase. Its cargo area dimensions are 117.51 in. in length, 83.68 in. in width, and 82 in. in height, offering 412.1 cu. ft. of space. It has a maximum payload capacity of up to 3,580 lbs. and a GVWR of up to 11,000 lbs.
The Chevrolet BrightDrop 400 is based on a dedicated EV platform and uses GM’s Ultium battery and drive technology, also found in its passenger vehicles. It is available in a FWD variant with 240 hp and 300 lb.-ft. of torque, and an AWD variant with 300 hp and 390 lb.-ft. of torque. Standard range is 159 miles in both variants. However, with an available bigger battery pack in the AWD variant, it extends up to 272 miles. Production of the Chevrolet BrightDrop 400 occurs alongside the Chevrolet BrightDrop 600 at GM’s CAMI Assembly Plant in Ingersoll (Ontario), Canada.
On June 30, 2022, former BrightDrop President and CEO Travis Katz told Bloomberg that the company planned to have an annual production capacity of over 50,000 EVs at this plant by 2025. The Zevo 400 was also part of the interaction, with Katz saying this is a great vehicle, particularly for uses like grocery delivery, where customers do shorter runs for delivering all the packages.
Mercedes Premium Vans
Mercedes-Benz Vans has confirmed new pure-electric premium commercial vans in the mid-size and large segments. The company will build the electric commercial vans on a new VAN.EA-C platform, purpose-built for diverse configurations and applications. This upcoming platform will be designed from the ground up for electric vehicles, ensuring enhanced spaciousness and efficiency compared to electric vans using modified internal combustion engine (ICE) vehicle platforms.
Running MB.OS vehicle software, the new electric Mercedes vans will be highly digital, supporting SAE Level 2 autonomous driving at launch. Mercedes-Benz Vans plans to introduce SAE Level 4 autonomous driving by 2030. Courier, express and parcel delivery (CEP) operators, hospitals, roadside assistance companies, and various service providers will find these electric Mercedes vans suitable for their needs. The first electric Mercedes premium van for commercial use is expected to launch in 2025.
Kia PV5
The Kia PV5, already previewed in a concept version, will be the brand’s first purpose-built vehicle, designed and engineered for electric power. This mid-size purpose-built vehicle is tailored for businesses like urban passenger mobility and cargo transportation. It is scheduled to arrive in mid-2025, and will be offered in Basic (passenger), Van (delivery), High Roof (delivery), and Chassis Cab versions.
The PV5 will feature a modern exterior with angular vertical DRLs, subtly placed headlamps, and aero wheels. The model will include OTA (Over the Air) and FoD (Feature on Demand) services. The passenger version is expected to have a minimalist interior, with easy ingress/egress through large sliding doors. It may also include a dashboard that resembles a sleek, desk-like surface, a compact steering wheel, and a freestanding portrait touchscreen infotainment system. Spy shots reveal A-pillar grab handles and light-bronze seatbelts. Large windows should provide the driver with excellent visibility.
The PV5 will be built on the ‘eS’ platform, part of Hyundai Motor Group’s Integrated Modular Architecture (IMA) system—an EV skateboard developed exclusively for PBVs. The Kia PV5 should be able to travel up to 600 km (373 miles) on a single charge and will have an indoor height of 1.8 m (5.9 ft.). Kia will manufacture the mid-size PBV at a dedicated factory within the Autoland Hwaseong production facility in Hwaseong-si, Gyeonggi-do, South Korea, with mass production starting in the second half of 2025. The company plans to produce 150,000 PBVs annually in the first full year. A Robo-Taxi version capable of Level 4 autonomous driving will follow, with a potential LiDAR on its roof.
Kia PV7
The Kia PV7 will come after the PV5 and its Robotaxi version. The Kia PV7 will be a large cargo delivery and multi-van measuring around 207.5 inches in length, 81.3 inches in width, and 83.5 inches in height, with a wheelbase of approximately 133.5 inches. Customers will be able to utilize this for people mover shuttle, mobile store/office van, delivery van, and refrigerated van purposes.
This large electric van will be released after the mid-size model discussed above.. Large logistics or distribution companies, shuttle service providers, ride-hailing service providers, small business owners, and contract drivers will also find the PV7 attractive because of its spacious and versatile interior. The Kia PV7 is scheduled to be built in the same new dedicated PBV plant in Hwaseong, South Korea.
Kia is also planning to establish an exclusive dealer network for commercial vehicles in almost every market where they plan to sell their vans. John Hargreaves has told Fleet News that Kia would need to establish a dealer network for after-sales coverage. Hargreaves is the company’s manager for fleet and remarketing in the UK, where the plan appears to involve the launch of a range of vans and a wide dealer network offering sales and service.
Blue Arc Delivery Van
Michigan-based The Shyft Group, formerly Spartan Motors, launched its EV brand, Blue Arc, on March 9, 2022. Among the confirmed products is a walk-in delivery van tailored for high-frequency, last-mile delivery fleets. The Blue Arc van offers 635-800 cubic feet of cargo space and a payload of up to 5,000 lbs. Its battery capacity ranges from 160-240 kWh with an 800V system voltage; at least one configuration provides a 150-mile range. An optional solar roof generates 1-2 kW. The van’s scalable chassis design (Class 3-5) varies in length from 12 to 22 feet. Key features include a 360-degree camera system, HD camera displays, automated entry, lane departure, and parking sensors.
The Shyft plans to begin production in Charlotte, Michigan. Shyft Group received CARB approval for its Class 3-5 Blue Arc EVs. The Class 3 Blue Arc EVs have a city range rating of 225 miles, while the EPA gives the Class 3 model with a 165 kWh battery a 200-mile range and 45 MPGe. On May 2, 2024, Shyft Group revealed that FedEx had ordered 150 units after a pilot on 8-10 hour routes in challenging conditions, including temperatures of 95ºF to 105ºF. Deliveries are still expected to begin in late 2024.
As the demand for sustainable and efficient delivery solutions grows, electric vans are positioned to play a pivotal role in the future of commercial transportation. With a variety of options becoming available, businesses have more choices than ever to meet their specific needs while reducing their carbon footprint.
