More companies are switching from diesel to electric forklifts and other material-handling equipment. This increases the demand for batteries—but also for solutions that make it easier to repair, disassemble, and recycle them once they have reached the end of their useful life.
Circular Battery Design is an innovation project aimed at developing a battery system in which disassembly and recycling are built into the design from the very beginning. The goal is to develop a battery system without adhesives, potting compounds, or other permanent joints, so that battery cells and materials can be systematically disassembled and recycled when the battery reaches the end of its life.
Designed for the Entire Battery Lifespan
The project focuses on the battery’s mechanical structure, module design, and assembly principles. The goal is to develop a battery system that not only meets the demands of industrial operation but also makes it easier to repair, maintain, and eventually dismantle the battery.
As part of the project, various battery cells, materials, and assembly methods are being investigated to identify the solutions that offer the highest recyclability and the lowest overall environmental impact. This knowledge will be translated into concrete design recommendations that can support the development of future circular battery systems.
From Design Principle to Prototype
The project is being carried out by MILA Nordic ApS in collaboration with DTU Energy Conversion and Storage, the Danish Technological Institute, and A/S N.P. Trucks Roskilde.
The project includes the development of a physical prototype that will enable testing of disassembly, cell removal, and handling in an industrial context. At the same time, design guidelines and a digital information concept are being developed to provide service and recycling operators with access to information on materials, safety, and disassembly.
Development and Testing Based at Risø
The project is being carried out with access to testing and development facilities at Risø, where DTU Energy is contributing expertise in battery technology, material selection, and the evaluation of circular battery concepts. MILA Nordic is also affiliated with DTU Link, which supports collaboration between industry, the research community, and testing facilities throughout the project period.
The project aims to establish a technical foundation for the further development and testing of circular battery systems for industrial vehicles and to contribute to more resource-efficient battery solutions.
Part of the Risø SME Innovation Platform
The project is one of 15 innovation projects within the Risø SME Innovation Platform, where companies and research institutions collaborate to develop and demonstrate new green technologies. The platform provides companies with access to research expertise, testing facilities, and strong innovation partnerships based at Risø.
Explore the other projects on the innovation platform
- PFASOL – PFAS in solar power plants – mapping and documentation of PFAS in solar power plants.
- OmniPFAS – flexible solutions for removing PFAS from various types of water.
- KhaosGuard – continuous monitoring of nitrous oxide emissions from wastewater treatment plants.
- RisøLith – 3D printing at the nanoscale at low temperatures.
- Circular solar-powered lighting – off-grid lighting with a focus on circularity and dark-sky principles.
- Heat-driven water-based cooling technology – utilization of excess heat for energy-efficient cooling.
- Reliable water supply – mobile solutions for producing safe drinking water.
- Searine M360 – electric propulsion system for small boats.
- Chemical plastic recycling – conversion of plastic waste into methanol.
- NanoShield – UV and nanotechnology that inhibits bacterial and algal growth on metal surfaces.
- Lab2Land – Greenlandic rock flour for carbon sequestration and soil improvement.
- 3D printing for flood protection – nature-based barriers printed directly into the landscape.
- Recycled Wind Turbines for 3D-Printed Homes – fiberglass from end-of-life wind turbines as a building material.
- Circular Plastic without Permanence – biodegradable plastic made from brewery waste.
- Circular Battery Design – battery systems designed for disassembly, repair, and reuse.
The project is part of the Risø SME Innovation Platform, which was developed as a coordinated initiative under the Investment Support Scheme for Green Innovative Technologies and is administered by Clean. The initiative is funded by REACT-EU funds administered by the Danish Board of Business Development.
