A Swiss-led research team has unveiled an advanced robotic system designed to dismantle and repurpose used electric vehicle batteries, marking a major leap forward in sustainable battery lifecycle management. The project, focused on second-life applications and robotic recycling, arrives as global EV adoption accelerates and the volume of end-of-life battery packs surges.
“We have developed innovative solutions that are attracting worldwide attention,” Andrea Vezzini, PhD, an industrial electronics professor at the Bern University of Applied Sciences (BFH) and project manager, said.
With electric vehicles becoming mainstream, traditional battery recycling methods are struggling to keep pace. Manual disassembly is slow, hazardous and expensive, limiting the flow of reusable materials back into the supply chain. The new robotic system automates the entire process, significantly reducing safety risks while increasing throughput.
Industry research shows that integrating robotics and artificial intelligence into disassembly lines could eliminate key bottlenecks in EV battery recycling. These systems can identify wiring layouts, locate fasteners and extract components with precision, allowing recyclers to handle diverse battery designs without exposing workers to high-voltage hazards.
The Swiss team’s two-phase workflow includes pack-level disassembly followed by module-level separation into cells. Early tests indicate that the automated system can perform the task up to ten times faster than human workers. This speed, combined with consistent precision, leads to higher material recovery rates and fewer incidents of overheating or module damage.
Beyond robotics, emerging recovery technologies are capable of reclaiming highly pure nickel, lithium and cobalt from spent batteries without harsh chemicals. These advancements are attracting major investments from global battery recyclers and automakers, signalling a shift toward a more circular and sustainable EV industry.
“These solutions represent a first step on the way to closing the battery loop with stations distributed around the globe,” Vezzini concluded in the official press release.
Recovered materials from EV batteries are economically valuable and strategically important. High-quality recycled metals can be fed back into new battery production, reducing reliance on mining and stabilising supply chains affected by geopolitical tensions and raw-material shortages. Countries worldwide are accelerating efforts to build domestic recycling capacity. Major firms in the United States and Europe are expanding battery recovery facilities to prepare for the sharp rise in EV battery waste expected by 2030.
Industry experts emphasise the need for standardised battery passports, harmonized pack designs and scalable robotic workflows to ensure recycling systems can handle industrial-scale volumes.
As millions of EVs approach the end of their service life, the world faces a looming wave of battery waste. Automated recycling systems offer a path to safer, faster and cleaner battery processing, essential for meeting sustainability targets and supporting a circular economy.