The impact of battery design choices on recyclability and material recovery

Why Battery Design Matters for Recycling

As the demand for electric vehicles and energy storage systems accelerates, lithium-ion batteries are more prevalent than ever. Yet while performance, cost, and lifespan dominate the conversation, one critical factor often goes overlooked: how OEM battery systems are designed directly impacts their recyclability and material recovery potential.

From the shape of modules to how cells are fixed, OEM lithium-ion battery systems can either enable a smooth end-of-life process — or become major obstacles in the recycling chain.

The Design Bottleneck in Recycling

Many batteries on the market today are not designed for efficient disassembly. OEMs often prioritize compactness, durability, or proprietary integration — which leads to batteries sealed with adhesives, complex welds, or non-standard geometries. These design choices make recycling more labor-intensive and hazardous, slowing down throughput and reducing the percentage of critical raw materials like lithium, cobalt, and nickel that can be recovered.

As recyclers face growing volumes of used batteries, complex OEM designs are now a bottleneck in achieving circular economy targets.

Safety and Automation Challenges

Poor design doesn’t just reduce efficiency — it also increases risks. Batteries that lack clear labeling or standardized layouts make it difficult to assess state of charge or chemistry. During disassembly, this can lead to short circuits, fires, or toxic exposure, especially if the process is manual.

Moreover, automated recycling solutions — key to scaling up — require a certain level of uniformity. OEM battery systems that deviate too far from standard formats make automation less viable, increasing costs and limiting scalability.

Opportunities for OEMs: Design for Disassembly

A growing number of forward-thinking OEMs are now embracing design-for-disassembly and design-for-second-life principles. By using modular layouts, standard fasteners, and minimal adhesives, manufacturers can vastly improve recyclability without compromising performance.

Not only does this reduce the environmental footprint of each battery pack, but it also helps OEMs comply with new regulations such as the EU Battery Regulation, which demands higher recovery rates and detailed battery tracking.

Collaboration is Key

To truly unlock circularity, collaboration between recyclers and OEMs is essential. By involving battery recycling experts early in the design process, manufacturers can anticipate end-of-life challenges and adapt accordingly. This proactive approach improves sustainability metrics, reduces future costs, and builds compliance into the product from day one.

Conclusion: Designing for the End, from the Start

OEM battery systems shape the entire lifecycle of lithium-ion batteries — not just their use, but their end. Better design means safer handling, higher material recovery, and greater compatibility with automated disassembly technologies.

At Circu Li-ion, we work with OEMs to improve battery circularity through intelligent design and cutting-edge dismantling systems. If you're building the next generation of battery systems, let’s make sure they’re future-proof — from first charge to final cycle.