Worried about EVs catching fire? The real risk is lower than you think

Many headlines fuel fear about EV fires, but the real numbers show electric cars are far safer than most drivers realize.

When something happens involving an electric vehicle, especially a Tesla, it is always in the news. And when the story involves fire or injury, it spreads like wildfire.

That was the case with Michael Sheehan, a Texas man who tragically died after his Tesla Cybertruck caught fire following a crash. According to reports, the vehicle’s electronic doors failed, possibly due to a power loss caused by the collision. As the truck became engulfed in flames, Sheehan was unable to escape. His family has since filed a lawsuit against Tesla, claiming critical design flaws turned a survivable crash into a fatal incident.

This isn’t the first time an electric car has made news for the wrong reasons, and it likely won’t be the last. But while the headlines are alarming, they don’t always tell the whole story. To understand the reality of the risk, it’s worth taking a closer look at the data behind EV fires, how often they occur, what causes them, and how they compare to traditional gas-powered cars.

The truth about fire risk

Imagine that someone in 2025 stood up in a safety meeting and said, “I have a great idea! Let’s build a vehicle that runs on a flammable liquid. We’ll install an engine at the front that runs on small explosions, and just beneath the seats, we’ll store approximately 20 gallons of gasoline. Then we’ll take it on the highway at 70 miles per hour with the whole family inside.” That pitch would be laughed out of the room.

And yet, this is exactly what the modern combustion engine is. The only reason it feels normal is because we’ve lived with it for over a century.

Now, with electric vehicles, the conversation is flipped. People are asking, “Is it really safe to sit above a 100 kilowatt-hour battery?” “What happens if it catches fire?”

A battery fire is unfamiliar, visually intense, and often unpredictable. However, when examining the numbers, the story becomes far more nuanced.

It is not easy to find reliable data, but according to EV FireSafe, only 0.0012 percent of electric passenger vehicles experienced a battery fire between 2010 and 2022. Others report slightly higher rates, with a 0.025% chance of EVs catching fire compared to internal combustion engine vehicles, which have a 1.5% chance. This means ICE cars are much more likely to catch fire than electric ones.

In other studies, gas-powered cars experience approximately 1,530 fires per 100,000 vehicles, while EVs average just 25 fires per 100,000. The difference is staggering.

Why fires happen in EVs

Electric vehicle fires are different in nature from those in gas-powered cars. They don’t ignite from leaking fuel or engine oil. Instead, the danger lies in the lithium-ion battery pack. These powerful, high-voltage systems are generally safe, but can fail in rare and specific ways.

At the center of the issue is a phenomenon known as thermal runaway. This occurs when a single battery cell overheats, triggering a chain reaction in neighboring cells. It can be caused by several factors, such as a severe crash, an internal short circuit, a manufacturing defect, or exposure to external heat. Once this reaction begins, it generates intense heat and flammable gases, often leading to a fire that is both difficult to extinguish and prone to reignition.

Thankfully, the technology is steadily improving. Modern battery management systems can detect overheating early and shut the system down before it escalates. Manufacturers are also shifting toward safer battery chemistries, like lithium iron phosphate (LFP), which are less prone to thermal runaway. Fire-resistant casings and automatic disconnects are becoming standard.

In the case of the Cybertruck fire in Texas that claimed the life of Michael Sheehan, the exact cause of the fire remains unclear. The vehicle struck a tree at a relatively low speed, yet the aftermath was catastrophic. Investigators have not yet confirmed whether the fire originated from the battery or another source. But in this instance, the larger concern isn’t just the fire; it’s why the driver couldn’t escape.

According to the lawsuit, the vehicle lost power after the crash, making it impossible to open the electronically controlled doors. Without a mechanical override or a way to break free, Sheehan remained trapped inside as the fire took hold. It’s a heartbreaking situation that raises urgent questions about safety features and emergency exits in modern EVs.

While the full investigation is still ongoing, it is hoped that it will provide clarity. If it reveals a design flaw, it will be critical for the automaker to take responsibility and make changes. Because no matter how advanced a vehicle may be, safety must always come first, and no driver should ever be locked inside a burning car.

EV fire safety

When an electric vehicle catches fire, putting it out isn’t as simple as grabbing a fire extinguisher. Unlike gasoline fires, which can often be contained quickly once the fuel source is removed, EV battery fires are far more complex and stubborn.

Once a battery cell enters thermal runaway, it can trigger a cascade throughout the entire battery pack. The fire can burn at high temperatures, release toxic gases, and even reignite hours after it appears to be extinguished.

Standard firefighting methods don’t always apply. Foam and dry chemical extinguishers are largely ineffective. That’s why many departments around the world are undergoing specialized EV fire training, investing in thermal imaging cameras, submersion tanks, and even battery fire blankets. In certain situations, the most effective strategy is to let the vehicle burn under controlled conditions, ensuring the safety of people and property.

As EV adoption grows, so does the importance of public awareness. Here’s what you should do if you ever encounter an EV fire:

• Get away immediately: If you suspect smoke, sparks, or a fire, stop the vehicle and exit right away. Move at least 100 feet from the car and warn others to do the same.
• Do not open the hood or trunk: In an EV, this can feed oxygen to the fire or expose you to dangerous gases.
• Call 911: Report that the vehicle is electric so fire crews can respond appropriately.
• Do not attempt to put out the fire yourself: Even if flames aren’t visible, a smoldering battery can explode or reignite suddenly.
• Watch for delayed reactions: EV fires can start or restart long after a crash or impact, so stay alert and keep your distance even after the fire appears out.

These steps could save lives. While EVs are statistically less likely to catch fire than traditional cars, the fires they do experience require a very different level of care and response.