Economics of Electric Vehicle Corridor Fast Charging in the United States

Corridor direct-current fast charging (DCFC) stations enable long-distance electric vehicle travel, yet their economics remain uncertain due to high capital costs, low initial utilization, and exposure to utility demand charges. This study evaluates the long-term economics of corridor DCFC across the United States, incorporating capital and operating expenses-including charging equipment and real-world utility tariffs-alongside modeled station utilization, financial incentives, and ancillary retail revenue. In the Baseline scenario, modeled breakeven costs for corridor DCFC average $0.42/kWh over 20 years, yet fewer than half of stations reach cost parity with gasoline on a per-mile basis. Utilization is the primary driver of cost variation, with low-utilization stations costing roughly six times more per kilowatt-hour than the national average. Excluding stations that fail to reach cost parity reduces National Highway System coverage within 50 miles from 94% to 67%, underscoring the trade-off between market-driven deployment and comprehensive network coverage. These results provide guidance for charging providers, utilities, planners, and policymakers seeking to develop and sustain a financially viable national corridor charging network.. Authors: Borlaug, Brennan [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000191421641); Caristo, Vince [National Laboratory of the Rockies, Golden, CO (United States)]; Ouren, Fletcher [National Laboratory of the Rockies, Golden, CO (United States)]; Yang, Fan [National Laboratory of the Rockies, Golden, CO (United States)]; Wood, Eric [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000291771104). DOE Contract: AC36-08GO28308. Subjects: 32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; charging costs; charging infrastructure; corridor charging; DCFC; electric vehicle