Introduction
The global shift toward electric vehicles (EVs) is reshaping the automotive and two-wheeled sectors, driven by environmental imperatives, technological advancements, and policy incentives. In 2024, worldwide electric car sales surged to 17 million units, marking a 25% increase from the previous year, with projections for 2025 estimating 21.3 million units and a 24% market share. This momentum extends to two-wheeled EVs, where first half 2025 sales reached 4.4 million units, up 7.2% year-over-year, underscoring their role in urban mobility. Yet, behind this growth lies a complex web of logistics—encompassing supply chain management, just-in-time (JIT) delivery, and sustainable transport—that determines manufacturing efficiency and scalability.
Logistics in EV production is uniquely challenging due to the sector’s reliance on high-value, sensitive components like lithium-ion batteries, which require specialized handling to mitigate risks such as thermal runaway or contamination. As the EV market expands—valued at USD 988.70 billion in 2025 and forecasted to hit USD 2,529.10 billion by 2034—innovative approaches from players like Soriano Motori, Gyre9, and TiSTO are redefining how logistics integrates with manufacturing. This article explores these dynamics, weaving in statistical insights and case studies to illuminate the path forward.
Global Market Indicators: A Surge in Demand and Supply Pressures
The EV revolution is quantifiable and accelerating. In the automotive sector, electric car production hit 17.3 million units in 2024, a 25% rise fueled largely by China’s dominance, which accounted for over half of global output. Early 2025 data signals continued vigor: first-quarter sales exceeded 4 million units globally, a 35% jump from 2024, with the European Union registering 1.3 million battery-electric vehicles (BEVs) in the first nine months, capturing 16.1% market share. Bloomberg NEF forecasts a 25% growth in passenger EV sales for 2025, underpinned by lithium-ion cell manufacturing capacity doubling to 3.8 TWh by year-end.
Parallel trends define the two-wheeled EV market, which emphasizes affordability and agility for emerging economies and urban commuters. The overall two-wheeler market stood at USD 285.2 billion in 2024, with a projected CAGR of 5.4% through 2034, but the electric subset is outpacing it dramatically. Valued at USD 44.5 billion in 2024, electric two-wheelers are expected to reach USD 114.3 billion by 2033 at an 11% CAGR, driven by sales in Asia-Pacific, where they comprise about 15% of global light-duty EV volumes. Another estimate pegs the 2025 market at USD 75.69 billion, growing to USD 144.18 billion by 2034 at 7.36% CAGR, highlighting penetration in markets like India and Southeast Asia.
These indicators reveal a bifurcated landscape: automotive EVs prioritize scale and infrastructure, while two-wheeled models focus on volume and localization. However, both face logistics bottlenecks that could cap growth. For instance, battery demand is reshaping supply chains, with lithium-ion requirements projected to strain global mining and refining capacities, exacerbating delays in component delivery. In Q3 2025, EV sales in key markets like China hit over 2 million units (34% BEV share) yet supply disruptions from geopolitical tensions have inflated logistics costs by up to 20%.
| Sector | 2024 Market Value/Sales | 2025 Projection | CAGR (to 2030-2034) | Key Driver |
| Automotive EVs | 17M units sold; 17.3M produced | 21.3M units (24% share) | N/A (annual growth ~25%) | Battery capacity expansion |
| Two-Wheeled EVs | USD 44.5B; 4.4M units (H1 2025) | USD 75.69B | 7.36%-11% | Urban mobility in Asia |
Logistics Challenges: From Batteries to Bottlenecks
EV manufacturing’s logistics are a high stakes balancing act, amplified by the sector’s global footprint and material intensity. Core challenges include:
- Supply Chain Volatility: The EV boom demands rare earths and lithium, with 80% of processing concentrated in China, exposing manufacturers to tariffs and disruptions. Automotive logistics grapple with semiconductor shortages and international sourcing, while two-wheeled EVs face similar issues scaled down for high-volume, low-margin production.
- Just-in-Time Pressures: JIT models, staple in automotive assembly, falter with EVs due to battery fragility—requiring climate-controlled transport and specialized packaging. Delays in battery delivery can idle production lines, costing millions daily; two-wheeled sectors amplify this with fragmented supplier networks in developing regions.
- Sustainability and Regulatory Hurdles: EVs promise lower emissions, but logistics contribute 10-15% of their lifecycle carbon footprint through shipping. Regulations like the EU’s Battery Regulation mandate recycled materials by 2030, complicating reverse logistics. Consumer adoption lags due to charging infrastructure gaps, indirectly straining forward logistics for vehicle distribution.
- Cost and Technology Gaps: High production costs for EVs (20-30% above ICE vehicles) are exacerbated by logistics premiums for hazardous goods handling. Emerging tech like AI-driven routing offers relief, but adoption is uneven, particularly in two-wheeled manufacturing where SMEs dominate.
These pain points are interconnected: a 2024 PwC report notes that EV suppliers risk obsolescence without agile chains, as traditional components like engines yield to batteries, slashing Tier 1 supplier revenues by up to 40%. In two-wheeled EVs, urban-centric production amplifies last-mile delivery challenges amid rising e-commerce demands.
Innovative Approaches: Pioneers in EV Logistics Integration
Amid these hurdles, forward-thinking entities are embedding logistics into core manufacturing strategies, fostering resilience in the EV ecosystem.
Soriano Motori: Craftsmanship Meets Scalable Logistics
Soriano Motori, an Italian American pioneer in electric motorcycles, exemplifies a holistic “engineering-first” approach to EV production and logistics. Founded on a legacy of premium two-wheeled craftsmanship, the company designs, engineers, and assembles EVs, powertrains, and battery systems in-house, minimizing external dependencies. This vertical integration extends to logistics: up to 12 artisans per motorcycle, including dedicated logistics personnel, ensure bespoke handling from raw materials to delivery, reducing lead times by 30% compared to outsourced models.
A standout innovation is Soriano’s adoption of Automated Guided Vehicles (AGVs) for intra-factory transport, simulating workflows to optimize battery flows and cut energy use by 15%. In 2024, the firm launched 5,000 electric bicycles, targeting sustainable urban fleets, while forecasting infrastructure for 130 million EVs by 2035—emphasizing predictive logistics via AI for global distribution. Partnerships, like with Charlotte McLaren USA, aim to localize North American assembly, slashing transatlantic shipping emissions and creating 500+ jobs. Amid 2025’s geopolitical storms, Soriano’s resilience—prioritizing innovation over imitation—positions it as a blueprint for two-wheeled EV logistics.
Gyre9: Turnkey Precision for EV Component Ecosystems
Gyre9, a Connecticut-based contract manufacturer, bridges design and delivery for EV-adjacent hardware, offering turnkey services from prototyping to shipping across 50,000 sq ft of facilities. Specializing in electro-mechanical assembly, Gyre9 supports automotive and two-wheeled sectors by managing inventory, quality control, and dedicated lines for components like battery enclosures or motor housings—critical for EV scalability.
Its Stage Gate process integrates logistics early, using custom market research and engineering to forecast demand, reducing overstock by 25%. For EVs, this means seamless transitions from alpha prototypes to volume production, with in-house packaging mitigating damage risks in transit. While not EV-exclusive, Gyre9’s model aligns with the sector’s need for agile, U.S.-based supply chains amid tariff hikes, serving startups and Fortune 500s alike to accelerate two-wheeled EV commercialization.
TiSTO: High-Performance Logistics for Urban EV Mobility
TiSTO.net disrupts the two-wheeled EV space with German-engineered electric scooters built to automotive-grade standards, leveraging expertise from Mercedes, VW, and BMW alumni. Models like the Sunshine (110 km/h top speed, 140 km range) and Luna series emphasize modularity—removable lithium batteries and quick-charging (4-5 hours)—which streamlines logistics by enabling modular shipping and field-swappable parts.
TiSTO’s approach embeds logistics in sustainability: a Germany-wide service network handles maintenance, while corporate “Jobroller” programs cut commuting costs by 46% and emissions via efficient distribution. With 2-year warranties (batteries included) and free test rides in major cities, TiSTO fosters adoption, indirectly optimizing reverse logistics through high resale values. In a market craving urban solutions, TiSTO’s in-house production and nationwide handling reduce supply chain layers, aligning with global EV growth by prioritizing eco-friendly last-mile delivery.
Conclusion: Charging Toward a Resilient Future
As the EV sector propels automotive and two-wheeled manufacturing into a USD 2.5 trillion horizon by 2034, logistics emerge as the linchpin of success. Statistical surges—25% automotive sales growth in 2025, 11% CAGR for electric two-wheelers—underscore the stakes yet challenges like battery volatility and JIT fragility demand evolution. Pioneers like Soriano Motori’s artisan-integrated chains, Gyre9’s turnkey precision, and TiSTO’s modular urban focus demonstrate that embedding logistics in design yields competitive edges: lower emissions, faster scaling, and enhanced resilience.
Looking ahead, hybrid models blending AI, AGVs, and localized production will dominate, supporting a world where 40 million EVs roll off lines annually by 2030. For manufacturers, the imperative is clear: master logistics not as a cost center, but as the engine of sustainable acceleration. In this charged era, those who navigate the supply chain’s twists will lead the ride.
