EV Battery Disassembly Using AI and Robotics Hits Milestone in Recirculate Project

AI and Robotics Revolutionize EV Battery Disassembly

Recirculate, a Finnish-led EU project, has achieved a major milestone in EV battery disassembly using AI and robotics. The project’s first-phase success marks a critical leap toward safer, more efficient recycling of electric vehicle batteries. With global EV adoption surging, automating disassembly is becoming essential for sustainable end-of-life battery management.

The Recirculate team, supported by Centria University of Applied Sciences, developed a robotic cell based on a KUKA KR10 industrial robot. This robot dismantles batteries in two stages—first from pack to module, then from module to cell. Using AI-trained machine learning models, the system detects and unscrews each component autonomously, analyzing depth and positioning with millimeter accuracy. “There are approximately 50 screws on the lid alone,” notes Centria’s Tomi Pitkäaho, underscoring the complexity and need for precision.

Notably, the system doesn’t rely on QR codes or digital product passports. Instead, it uses a battery identification model to recognize battery types, including those from Tesla and Ford, with near-perfect accuracy. This innovation allows the robot to automatically select the appropriate disassembly program, making the solution highly scalable and adaptable across OEMs.

Scaling EV Battery Disassembly Using AI and Robotics

The project’s next step involves expanding its proprietary AI training dataset to support a broader range of battery chemistries and pack designs. This data-driven approach enhances the robot’s capacity to handle different wiring configurations, connectors, and materials without human intervention.

Recirculate’s approach addresses a key bottleneck in battery recycling: manual disassembly. Traditional methods are slow, hazardous, and not cost-effective at scale. By automating these tasks, Recirculate unlocks new efficiencies in the critical materials recovery process, including lithium, cobalt, and nickel—essential elements in the EV supply chain.

Moreover, the project sets a precedent for other EU-backed initiatives looking to strengthen Europe’s strategic autonomy in battery materials and reduce dependency on raw material imports. As battery volumes rise, innovations like Recirculate’s AI-powered robotic system will become essential infrastructure in the circular economy.

SuperMetalPrice Commentary:

Recirculate’s breakthrough in EV battery disassembly using AI and robotics reflects a significant shift toward automation in battery recycling. This approach not only reduces labor risks and costs but also strengthens the supply chain for critical battery materials. As machine learning models continue to evolve, we expect similar systems to emerge across North America and Asia. Companies investing early in automated disassembly infrastructure could gain a strategic edge in securing recycled lithium, cobalt, and nickel for next-gen battery production.