German researchers are developing a robot-assisted system that could give old electric vehicle (EV) batteries a second life, rather than destroying them through conventional recycling methods.

The initiative, called RoB@t2Cell, aims to automate the safe dismantling, analysis, and targeted discharge of used battery cells for reuse and recycling. It is carried out by the Fraunhofer Institute for Manufacturing Engineering and Automation IPA in Stuttgart, and other industrial and research partners.

The researchers revealed that EV batteries retain significant residual voltage after use, which creates safety risks during recycling. This is why, to reduce the risks, they are deeply discharged before processing, which, in turn, can permanently damage otherwise functional cells.

To address the challenge, the Fraunhofer IPA research team began developing a robotic system capable of deciding whether individual battery cells should be reused, remanufactured, or fully recycled.

Repurposing EV batteries

For the project, funded by Germany’s Federal Ministry for Research, Technology and Space (BMFTR), the team created a robot-assisted dismantling and discharge platform that can selectively process battery cells depending on their future use.

Depending on the planned reuse pathway, reuse, remanufacturing or recycling, the discharge process can be individually adjusted,” the researchers explained. “Battery cells and modules intended for recycling are deeply discharged, while cells intended for reuse are gently brought to a defined state of charge.”

According to the scientists, this targeted approach could help reduce waste and recover more value from aging EV batteries. “This preserves valuable cells and allows them to be prepared for future reuse,” they continued.

The new technology integrates automated contacting systems, intelligent battery characterization, real-time decision-making, and adaptive discharge mechanisms into an integrated platform.

“The dismantling process, including exposure of the cell terminals, is carried out using an advanced robotic cell that meets the highest standards in safety, high-voltage engineering, and software technology,” the team added.

Automated battery recovery

As per the researchers, the system can safely disassemble battery packs down to the cell level while exposing the cell terminals for testing and processing. It also meets high safety, software, and high-voltage engineering requirements.

Following development, it will undergo industrial pilot testing at the advanced materials and recycling company Umicore. What’s more, the scientists are also focusing on newer adhesive-bonded battery systems, which are considered especially difficult to dismantle and recycle efficiently.

In addition to EV battery reuse, the project also targets improvements in material recovery. For batteries that must be recycled, the team is building automated dismantling and cell-opening technologies that prepare the cells for a water-based recycling process.

Unlike conventional approaches, the system can reportedly process batteries that have not been fully deep-discharged while improving the recovery of critical raw materials. It builds on earlier work from the DeMoBat project, which showed the industrial feasibility of automated battery dismantling.