Optimization of e-car battery reuse: a research project

Reuse Computer tomography examines car batteries

2025-02-07 From Stefanie Eckardt | Translated by AI 2 min Reading Time

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What usually detects bone fractures is now intended to examine used e-car batteries. Wuppertal researchers use computer tomography to analyze the condition of the cells.

Whether used high-voltage batteries are sent for recycling (as done here at Mercedes-Benz) or continue to be used depends on their condition.(Image: Mercedes-Benz) — Whether used high-voltage batteries are sent for recycling (as done here at Mercedes-Benz) or continue to be used depends on their condition.
(Image: Mercedes-Benz)

The question of how old batteries from electric vehicles can be sensibly reused is at the center of the research project "Re-Use of Battery Cells: CT Analysis of Lithium-Ion Batteries to Assess Function- and Safety-Critical Features for the Second Life Phase" (short: RELIBRE). Researchers are investigating how computed tomography (CT) can be used to analyze the relationships between the use and aging of battery cells.

Importance of lithium-ion batteries

In light of the increasing prevalence of electric vehicles, lithium-ion batteries are gaining in importance. As these batteries age, the question arises of how to assess their remaining performance and analyze their reusability.

Lifetime and second-life use

To enable the suitability of the batteries for a second life cycle (known as second life), it is crucial to quantify and assess the aging of the batteries. This allows conclusions to be drawn about the performance and safety-related aspects of the batteries.

Computed tomography has the potential to examine the interior of battery cells without needing to open them. This allows changes inside the battery cell that affect aging to be made visible non-destructively, according to University of Wuppertal (Germany). Project leader Prof. Stefan Bracke expects that the more precise examination of the aging state will lead to a better assessment of the batteries' second-life capability.

The project also investigates the interactions between the use of the batteries in the first life cycle and the changes that occur during manufacturing and use. Using statistical methods, the researchers aim to analyze the connections and draw conclusions about the causes of the aging processes.

Research partners and funding

The project is supported by a consortium of industrial companies and scientific institutions. Diondo GmbH, a manufacturer of industrial computed tomographs, leads the consortium and is responsible for developing standardized CT measurement methods as well as the CT examinations of battery cells. The disposal specialist Elorec undertakes the measurement and examination of the battery cells in their current state, as well as the analysis of complementary, non-destructive battery testing methods.

The project is funded by the German Federal Environmental Foundation with more than 140,000 euros (145.250 USD).

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Date: 08.12.2025

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