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At this year’s Cenex Expo, a significant step toward battery sustainability was on display: electric vehicle (EV) battery cells manufactured entirely from recycled materials. The prototype cells were developed using Altilium’s EcoCathode recycling technology, with support from Jaguar Land Rover (JLR).
The demonstration included automotive-grade NMC 811 multilayer pouch cells, produced from cathode active material (CAM) extracted from end-of-life EV batteries. According to Interesting Engineering, Initial testing has shown that the performance of these cells is comparable to that of new batteries made from virgin materials. JLR is currently conducting full-scale validation at its battery testing facilities.
In addition to the multilayer cells, the project also showcased single-layer pouch cells made with 100% recycled cathode and graphite anode materials. These were integrated into a virtual reality model of a Jaguar I-PACE battery pack.
The effort is part of a broader strategy to establish a circular economy for EV batteries in the UK. According to an independent Life Cycle Assessment (LCA) conducted by Minviro, cells produced with 100% recycled CAM in the UK could reduce greenhouse gas emissions by 32% compared to similar cells manufactured in Asia using virgin materials.
Other environmental benefits included 58% reduction in freshwater ecotoxicity, 30% decrease in particulate matter formation and a 38% lower demand for virgin metal and mineral resources.
The recycled materials used in the cells come from Altilium’s EcoCathode process, which recovers over 95% of critical cathode metals and more than 99% of graphite from battery waste. These recovered inputs are then upcycled into high-quality battery-grade materials suitable for reuse.
The project receives support through the Advanced Propulsion Centre UK’s Route to Market Demonstrator initiative and aligns with upcoming EU regulations mandating recycled content thresholds for EV batteries.
By advancing domestic recycling capabilities, the UK is positioning itself to meet regulatory targets while reducing dependency on imported raw materials.
