The growing presence of EVs on European roads brings with it the pressing need for sustainable battery recycling solutions. LIBs contain valuable raw materials, but also present significant challenges when it comes to disassembly due to their complexity, residual energy, and toxic components. Current dismantling procedures are predominantly manual, exposing operators to hazards such as electric shock and harmful substances. Moreover, the manual approach lacks the consistency and speed required for large-scale operations.
To address this challenge, EURECAT has developed in the frame of FREE4LIB a robotic dismantling process focusing on automating two of the most critical and hazardous steps: unscrewing and battery lid removal. Four main criteria were used to determine which dismantling tasks should be automated: complexity, safety, repetitiveness, and process impact. Based on these factors, unscrewing and lid removal were selected as high-value targets for robotic automation due to their frequency, precision requirements, and importance in the broader disassembly workflow. These steps are indeed fundamental for accessing the battery's internal modules and ensuring subsequent safe handling, recycling, or repurposing.
Validated in a laboratory environment (TRL 5), the developed solution demonstrates increased efficiency, improved safety, and adaptability across different battery models—paving the way for scalable, industrial implementation in the circular battery economy. A video demonstration is available to showcase the robot inaction, performing both tasks autonomously.
In collaboration with Watt4Ever, Eurecat conceptualised and validated a robot-based process for dismantling EV battery packs. It focuses on automating high-risk and labour-intensive stages while allowing for human-robot collaboration where necessary.
A preliminary analysis of the dismantling process, conducted by Watt4Ever, mapped out the various stages, identifying those that were most costly, risky, or repetitive.EURECAT then developed robotic solutions targeting the unscrewing and lid removal operations, tested under laboratory conditions to reach Technology Readiness Level 5 (TRL 5).
The robotic systems were designed to be adaptable, CAD-independent, and compatible with different battery types. Artificial vision and advanced toolsets enable dynamic response to real-time conditions, a critical feature for handling used or damaged batteries.
Robotic system:design and implementation
The unscrewing task was assigned to a collaborative robot (UR10e), chosen for its precise force control and easy integration inhuman-shared workspaces. A machine vision system guides the robot to identify screws based on a trained dataset, enabling real-time adaptation without prior CAD data.
For lid removal, the robot is equipped with suction and vacuum mechanisms supported by a vision-based positioning system. It performs all necessary steps: aligning over the lid, securing it, lifting, and transporting it to a designated drop-off point. This setup allows safe handling of heavy components while ensuring that the battery’s internal structurer emains undamaged.
Both systems are agnostic to battery brand and model, tested successfully on used EV batteries units, and demonstrated high flexibility and adaptability in handling different configurations.
Testing andvalidation
Rigorous testing in controlled environments confirmed the performance of both robotic tasks. Systems were evaluated on adaptability, reliability, and integration capability. In each case, the robots performed autonomously with high precision, consistency, and minimal operator intervention.
The use of real EV batteries, alongside dummy prototypes, allowed validation in both ideal and realistic conditions. Crucially, these trials confirmed that the robotic systems can scale and adapt to industrial requirements with limited reconfiguration.
To illustrate this, a video demonstration has been developed (see above), showcasing how the robot autonomously performs the unscrewing and lid removal tasks in alab setting. This visual material offers clear proof of concept for stakeholders exploring the transition to automated battery recycling.
Results and performance evaluation
Both applications demonstrated significant advantages over manual processes. The robot vision models reliably detected all screw types while eliminating false positives. Process speed and accuracy were enhanced, and safety was significantly improved by reducing human involvement in high-risk steps.
The flexibility of the robotised solution—particularly its independence from battery-specific CAD files—was a critical success factor. This makes the solution scalable and suitable for real-world recycling scenarios where battery condition and model may vary widely.
Lessons learnt and next steps
This breakthrough confirms that robotic dismantling of EV batteries is no longer a future ambition but a proven and viable approach. By automating critical tasks like unscrewing and lid removal, EURECAT has demonstrated how robotics can enhance efficiency, ensure safety, and contribute to a circular economy.
The successful validation at TRL 5 marks an important step toward full industrial integration. With further scale-up, this technology can support Europe’s transition to a cleaner, more sustainable transport sector.
Next steps include extending robotic automation to other dismantling phases and integrating the system into broader industrial recycling lines. Further optimisation will aim to enhance cycle time and operational robustness. As EV deployment continues to rise, solutions like this will be essential to building a sustainable battery ecosystem.
