Electric vehicles and home charging stations are becoming increasingly common in Bulgaria, but behind the convenience lies a potential risk that many users are unlikely to be aware of: the danger of fire. The recently held Black Hat USA 2025 conference shed light on this worrying aspect of rapidly developing technology.
On 07.08.2025, researchers Jonathan Anderson and Thanos Kaliyanakis from Trend Zero Day Initiative™ (ZDI) presented their findings during a session titled "Peril at the Plug: Investigating EV Charger Security and Safety Failures". Before an audience of experts, they revealed vulnerabilities in the communication between the electric vehicle and the charging station that can lead to serious consequences.
A key point is the so-called "digital handshake" – the process by which the car and the charging station agree on the amount of current. The problem lies in the fact that the charging station, by default, trusts the signals sent by the electric vehicle. If these signals are compromised or manipulated – for example, through a hacker attack or software error – the station may supply much more current than it is designed to handle.
According to the researchers, in controlled tests they managed to make charging stations, complying with national and international standards, supply 80 amps of current – twice their standard limit (usually 40A or 48A). The result was dramatic: the cables reached temperatures above 170°C, which led to melting of the insulation and created conditions for a fire. Even more worrying is that none of the tested devices stopped automatically, and some even reported lower load, while the cables were actually overheating, illustrating the potential danger of inadequate reactions.
This raises the important question of the effectiveness of existing standards. While charging stations meet national and international requirements, this does not guarantee absolute safety. For example, a 48A charging station is usually connected to a 60A fuse. In the event of an overload (e.g., 80A), the fuse will trip, but sometimes only after about an hour. This period of time is sufficient for overheating and potential fire, especially if the car is charging overnight, when the lack of supervision can increase the risk.
In view of this, experts such as 11kwh.com emphasize the need for additional hardware protections to prevent the supply of current above the permissible limit, regardless of the signals from the electric vehicle. This is a simple, inexpensive and extremely effective way to reduce the risk. In addition, professional installation and regular maintenance are essential for safety. Electric vehicle owners can contribute to this by following the recommendations for safe charging.
The atmosphere of alarm caused by the findings of the Black Hat USA 2025 conference clearly shows that the rapid development of electric vehicle technology should not overshadow the need for strict safety measures. Hardware protections, professional installation, regular maintenance and consumer awareness are key to making electric mobility a safe and convenient experience.
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