The C-Max Energi has a 7.6kWh battery. What’s the cost of this battery pack to Ford? I do not think it’s been reported. It has been stated that Ford makes the battery for the C-Max Energi. Tesla‘s Elon Musk has stated that the cost per kWh will fall “below $200, in the not-too-distant future.” A Department of Energy post by Dan Leistikow states that the current cost is about $470 per kWh (my estimate based on battery with 100 mile range at $17,000) and will drop to about $280 per kWh (battery with 100 mile range at $10,000) by 2015. Lux research states that the price per kWh will still be about $400 in 2020. Another optimistic projection is by McKinsey & Company, which predicts that prices will fall to $200 by 2020 from a current cost of about $500 to $600 per kWh. Let’s assume that Ford’s cost is $600 per kWh. That means that the C-Max Energi’s 7.6 kWh battery costs Ford $4560. With the Federal Tax credit of $3750 [$3750 was Ford's original conservative interpretation of the law, the IRS has now stated that the tax credit is $4,007], the cost of the battery which is most of the added cost of making the C-Max, is less than $1000. Interestingly, $1000 is also about the difference in price we were quoted for a C-Max Hybrid SEL and the C-Max Energi SEL we ordered when taking the Federal Tax Credit off the price of the Energi. In California, there is an additional $1500 tax credit. In essence, in California the government (state and federal), will pay you about $500 to buy a C-Max Energi rather than a C-Max. It’s for this reason that I think the popularity of the C-Max will be short lived. The C-Max Energi will be more popular as long as the tax credits are available.
Updated September 27, 2013.