Das Projektteam am Fraunhofer IWU, von links nach rechts: M.Eng. Christian Fritsch, Dr.-Ing. Rico Schmerler, Dr.-Ing. Thomas Hipke, M.Sc. David Löffler, Dipl.-Ing. Carsten Lies. Foto: Fraunhofer IWU
Many traction batteries still have 70–80% residual capacity after use in vehicles – too little for cars, but ideal for stationary storage solutions in households, businesses, or the energy industry. Instead of shredding old modules, the Fraunhofer Institute for Machine Tools and Forming Technology IWU is focusing on targeted repair and reuse. Together with EDAG Production Solutions, an automated pilot plant for the gentle dismantling of used high-voltage batteries is being built in Chemnitz.
Securing valuable materials, closing cycles: The innovative plant will dismantle batteries down to the cell level in a largely non-destructive manner. The goal is to make functional modules or cells usable for new applications – or to specifically replace defective units. This not only reduces the demand for newly produced components but also facilitates the separate recycling of valuable raw materials such as lithium or cobalt.
Automation, AI, and skilled worker training: The new plant is AI-supported, flexible, and safe – even with different battery types. An integrated diagnostic system checks the state of health (SoH) of the battery cells and determines their future use, for example, in stationary storage systems or even in new vehicle batteries.
In addition, a central data platform is being developed in Chemnitz to standardize dismantling and recycling processes. It will not only provide technical insights but also contribute to the development of new career profiles – for example, at the interface of mechanics, electrical engineering, and computer science.
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