Electric vehicle battery packs represent a critical component in modern transportation, integrating complex hardware and software systems to ensure performance, safety, and longevity. However, as EVs become more connected, they face increasing cybersecurity threats that target vulnerabilities in communication networks, firmware, and data integrity. Unlike general battery management system (BMS) cybersecurity, which covers broader aspects of monitoring and control, EV battery packs require specialized attention due to their integration with vehicle networks and external interfaces.

One of the primary attack vectors for EV battery packs is the Controller Area Network (CAN) bus, the backbone of in-vehicle communication. The CAN bus facilitates data exchange between the battery pack, BMS, and other vehicle systems, but its lack of inherent encryption makes it susceptible to exploitation. Researchers have demonstrated that malicious actors can inject false data packets into the CAN bus, spoofing critical parameters such as state of charge (SOC) or temperature readings. For instance, a manipulated SOC signal could force the battery to overcharge or undercharge, accelerating degradation or causing safety hazards. Another documented exploit involves flooding the CAN bus with high-priority messages, inducing a denial-of-service condition that disrupts communication between the BMS and battery pack.

Mitigating CAN bus vulnerabilities requires a multi-layered approach. Network segmentation isolates the battery pack’s communication channels from non-critical systems, reducing the attack surface. Implementing message authentication codes (MACs) or CAN-specific encryption protocols, such as CANsec or CAN FD with embedded security features, ensures data integrity. Intrusion detection systems (IDS) tailored for automotive networks can monitor CAN traffic for anomalies, flagging suspicious activity in real time. Some manufacturers have begun adopting hardware security modules (HSMs) to authenticate ECUs and prevent unauthorized access.

Over-the-air (OTA) updates present another cybersecurity challenge for EV battery packs. While OTA enables remote firmware upgrades and performance optimizations, it also introduces risks if update mechanisms are compromised. A poorly secured OTA system could allow attackers to push malicious firmware, altering battery behavior or disabling safety protocols. In one documented case, researchers exploited weak cryptographic signatures in an EV’s OTA process to install unauthorized software, demonstrating the potential for battery manipulation.

Secure OTA implementation relies on robust encryption and authentication. Public key infrastructure (PKI) ensures that updates are digitally signed by the manufacturer, preventing tampering. End-to-end encryption protects data during transmission, while secure boot mechanisms verify firmware integrity before installation. Additionally, OTA systems should incorporate rollback protection to prevent attackers from reverting to vulnerable firmware versions. Some automakers employ dual-bank memory architectures, allowing updates to be validated in a isolated environment before deployment.

Encryption methods play a pivotal role in safeguarding EV battery pack data. Sensitive information, such as battery health metrics or charging history, must be protected both at rest and in transit. Advanced Encryption Standard (AES-256) is widely used for encrypting stored data, while Transport Layer Security (TLS) secures communication between the vehicle and external networks. However, encryption alone is insufficient if key management is weak. Hardware-based key storage, such as trusted platform modules (TPMs), prevents unauthorized access to cryptographic keys, even if the vehicle’s software is compromised.

Recent exploits have highlighted the consequences of inadequate cybersecurity in EV battery packs. In 2022, a vulnerability in a popular EV model allowed researchers to remotely manipulate charging parameters via a compromised charging station, leading to abnormal battery stress. Another study revealed that certain EVs exposed diagnostic data through unsecured telematics interfaces, enabling attackers to infer driving patterns or battery conditions. These incidents underscore the need for comprehensive security frameworks that address both technical and procedural weaknesses.

Mitigation strategies extend beyond technical solutions to include supply chain security and lifecycle management. EV manufacturers must vet third-party components, such as battery cells or BMS hardware, for potential vulnerabilities. Regular penetration testing and red team exercises identify weaknesses before they can be exploited. Furthermore, cybersecurity must be prioritized during the design phase, adhering to standards such as ISO/SAE 21434, which outlines best practices for automotive cybersecurity engineering.

As EV adoption grows, so too will the sophistication of cyber threats targeting battery packs. Proactive measures, including secure communication protocols, rigorous OTA safeguards, and robust encryption, are essential to maintaining trust and safety in electric mobility. The industry must remain vigilant, continuously evolving its defenses to stay ahead of emerging risks.

The intersection of cybersecurity and battery technology demands collaboration across automakers, suppliers, and cybersecurity experts. By addressing vulnerabilities specific to EV battery packs, stakeholders can ensure that the benefits of electrification are not undermined by preventable security failures. Future advancements may include blockchain-based authentication for battery data or AI-driven anomaly detection, but the foundation lies in implementing today’s best practices with precision and rigor.

In summary, EV battery packs face unique cybersecurity challenges that require targeted solutions. From CAN bus exploits to OTA risks, each vulnerability demands a tailored response to protect both vehicle performance and passenger safety. The industry’s ability to mitigate these threats will play a decisive role in the sustainable future of transportation.