Why we should rethink the future of fleet vehicle architecture

Fleet electrification is often framed as a vehicle problem. Swap gas engines for batteries, add chargers, and the job is done. In this episode of The Fleet, host Chris Brandt speaks with Will Graylin, founder and CEO of Indigo Technologies, about why that mindset falls short.

Will explains that the next leap in fleet performance will come from rethinking vehicle architecture, charging, and operations as a single system. For fleet and business leaders facing rising costs, labor constraints, and increasing delivery complexity, the conversation offers a clearer path to improving both economics and experience.

Here are the top insights from the latest podcast.

Where do the biggest electric fleet vehicle challenges lie?

Most electric fleet vehicles today still rely on architecture designed for internal combustion engines. While motors and batteries have replaced engines and fuel tanks, many of the underlying design assumptions remain unchanged. According to Will, this limits how much value fleets can actually capture from electrification.

“Instead of just looking at the hardware and saying we’re going to swap out a motor for an engine, we’re going to swap out the gas tank for a battery…we’re looking at it through the lens of what the customer ultimately needs,” he says.

The design structure could impact charging time, and long-term durability. By rethinking vehicles from the wheels up, including eliminating traditional axles and freeing up space between the wheels, fleets can reduce vehicle weight and the issues that go with it. Lighter vehicles require smaller batteries, which lowers upfront costs and reduces charging time.

For fleet leaders, this shift could include lower cost per mile and vehicles that are simply better built for the kind of nonstop use fleets demand.

Why are safety and ergonomics actually economic issues?

Fleet vehicle design has a direct impact on driver safety, productivity, and long-term costs. In last mile delivery and service fleets, drivers may enter and exit vehicles hundreds of times per day. Traditional high-floor vehicles increase fatigue and injury risk over time.

Graylin explains how quickly these inefficiencies add up. “When you add these couple of steps up, multiply it by 150 to 200 steps, that’s like 30 flights of stairs every single day.” Over years of service, that physical toll becomes significant.

He notes that “slips, trips and falls are the number one injury issues that take them out of commission.” Low-entry, flat-floor vehicle designs reduce steps, improve stability, and make loading and unloading safer and faster.

For fleet and business leaders, fewer injuries mean drivers are safe and stay longer, and downtime is reduced, all of which directly support operational performance.

How does charging limit electric vehicle scalability?

Charging is often cited as one of the biggest barriers to fleet electrification, largely because it’s treated as a standalone infrastructure problem. Will argues that charging must be integrated into fleet operations from the start.

“Charging can be either a barrier or an enabler,” he says. “And right now it’s mostly a barrier.” Poorly planned charging leads to vehicle downtime, higher energy costs, and limited scalability.

Smart charging strategies allow fleets to support more vehicles using the same electrical capacity by balancing loads and shifting charging to off-peak hours. The goal, as Will describes it, is ensuring that “by the morning, everybody is topped up and ready to go.”

For fleet managers, the takeaway is clear. Vehicle choice, onboard charging, and charging software all need to work in sync. When they do, charging stops being a bottleneck and becomes something that actually helps fleets grow.

How does right-sizing fleet vehicles reduce cost-per-mile?

Another key insight from Will involves the mismatch between vehicle size and task. Many last mile deliveries involve small, lightweight packages but are served by large vehicles designed for heavier loads.

Will notes that 85% of e-commerce is less than five pounds, yet trucks often deliver on average less than 1.1 packages per stop. “Why have these big trucks going into neighborhoods delivering one package at a time?”

Right-sizing vehicles to specific routes improves efficiency, safety, and utilization. Smaller vehicles consume less energy, are easier to maneuver in dense areas, and improve visibility for drivers and pedestrians. Over time, matching vehicle size to the job reduces congestion and lowers operating costs.

A systems-level approach to electric fleet vehicle transformation

The broader message for fleet and business leaders is that electrification is not a single decision, but a systems-level transformation. Systems-level thinking means designing vehicles, charging, and operations together instead of separately. They all influence one another.

Will frames success around what he calls the two ‘E’s’ of experience and economics. Fleets that improve driver and customer experience while lowering cost per mile will be best positioned to scale.

As fleet operators navigate the next phase of electrification and automation, this conversation underscores a clear path forward. Rethink vehicle architecture. Integrate charging with operations. Design for real-world use cases. For leaders willing to take a broader view, the opportunity extends beyond cleaner vehicles to more resilient, efficient, and competitive fleet operations.

Talk with an Element fleet expert to find out more about how electric fleet vehicles, charging, and operations can work in sync as one system.