Large quantities of battery systems will be discarded from electric vehicles in the future. Non-destructive separation of used electric vehicle (EV) traction batteries enables a second life of battery components, extraction of high value secondary materials, and reduces the environmental footprint of recycling and separation processes. In this study, the key performance indicators (KPIs) for the second life application of spent EV batteries are identified. Three battery packs are analyzed in terms of the joining techniques used—and possible separation techniques—considering only direct recycling methods. The components that can be recovered from these batteries are evaluated against the KPIs. This study shows that all the batteries analyzed allow a second life in stationary and semi-stationary electrical storage systems and marine applications when used at the pack and module levels. Two packs can be reused in electric vehicles such as forklifts. However, the feasibility of re-use in micro-mobility and consumer electronics is very limited. This study shows that technically feasible separation methods are dictated and constrained by the joining techniques used. As welding and adhesive bonding pose challenges to separation processes, future efforts should prioritize ‘design for disassembly’ to ensure sustainable battery life cycle management.

The European industrial landscape is undergoing a transformation driven by the dual imperatives of achieving net-zero emissions and ensuring resource efficiency, as outlined in the EU's Net-Zero Industry Act and Critical Raw Materials Act. These regulations mandate the development of net-zero technologies within the EU and the establishment of a circular economy to enhance technological competitiveness and reduce reliance on third countries. The growing demand for 'Made in Europe' products, characterized by high quality, cost-effectiveness, and sustainability, presents a multi-centric design challenge that requires integrating innovative development strategies into engineering practice. This paper advocates the adoption of Simultaneous Engineering in product design, emphasizing the parallel development of products and their manufacturing processes to improve manufacturability, cost-effectiveness, and quality while reducing time to market. It explores methods such as Robust Design and Tolerance Design to effectively manage risk and uncertainty during development and addresses the challenge of multi-centric optimization through the Design for Excellence (DfX) paradigm, which allows for the simultaneous consideration of multiple performance criteria. Finally, it highlights the need to re-evaluate engineering education, advocating for the integration of these methodologies as core competencies to equip future engineers for the challenges of a rapidly changing industry on the path to competitive net-zero.

Ensuring the sustainability of battery production and usage is critical in today's energy landscape. The battery lifecycle demands 100% inspection of battery cells to optimize resource utilization and minimize waste. Establishing geometrical tolerance limits is crucial due to the lack of previous empirical data. Only by combining geometrical, gravimetric, electrical, and chemical parameters can a comprehensive condition assessment of battery cells be achieved. Setting tolerance limits too narrowly leads to high rejection rates, affecting both cell production and subsequent assembly into modules and packs. A flexible cell tester that inspects the geometrical conditions of battery cells is essential. This system adapts to a rapidly changing product portfolio and functions as a mobile device. The tester is useful not only in battery production but also for state estimation for second-life applications, significantly contributing to the sustainability of the battery lifecycle. The need for the inspection of geometrical battery cell parameters is given by the product specific deviation of dimensions. As the demand for batteries grows and the need for environmentally friendly production methods increases, the cell tester ensures efficient and sustainable battery cell production and utilization. This represents a crucial step toward a more sustainable future, meeting the dual goals of efficient production and waste minimization.