The RoB@t2Cell research project, initiated in spring 2026, is developing automated solutions for the safe disassembly and targeted discharge of battery cells to support both recycling and second-life applications. Coordinated by the Fraunhofer Institute for Manufacturing Engineering and Automation IPA, the effort aims to establish a sustainable circular economy for the German and European battery industry.
Battery modules can pose significant safety risks when they retain residual voltage. Conventional deep-discharge methods neutralize these risks but render cells unusable for further applications. RoB@t2Cell addresses this challenge by tailoring the discharge process to the intended downstream use: cells designated for material recycling undergo deep discharge, while those slated for reuse or remanufacturing are gently brought to a defined state of charge. This preserves valuable cells for second-life scenarios.
Central to the project is an integrated system that automates battery contacting, intelligent characterization, real-time decision-making, and controlled discharge of individual cells and modules. A robot cell designed for safe high-voltage handling and advanced software control performs the disassembly needed to expose cell terminals. Upon completion of development, this system will enter an industrial pilot phase at project partner Umicore.
RoB@t2Cell also explores automated techniques for processing batteries assembled with novel adhesive systems. For modules bound for recycling, efficient processes for automated disassembly and cell opening are under development. The prepared cells then enter an innovative water-based recycling process capable of handling both deeply discharged and intact cells, improving recovery rates for critical materials and ensuring compliance with upcoming EU battery regulations.
Building on the achievements of its predecessor, DeMoBat—which demonstrated industrial disassembly of battery modules and electric motors—RoB@t2Cell extends these capabilities down to the cell level. The solutions developed will form the basis for robust second-life applications and high-efficiency recycling workflows.
The project consortium, led by Umicore, includes acp systems AG, Fraunhofer IPA and IWKS, and the University of Stuttgart. Associated partners are BorgWarner Battery Systems Technical Center and Siemens. Running from January 2026 through December 2028, the initiative is funded by the German Federal Ministry for Research, Technology and Space with a total budget of €5.09 million. Fraunhofer IPA contributes expertise in digitalized battery cell production, lifecycle-optimized reuse strategies, modeling and simulation, as well as sustainability assessment.
Source: Fraunhofer IPA press release (https://www.ipa.fraunhofer.de/de/presse/presseinformationen/sichere-wiederverwendung-und-effizientes-recycling-von-altbatterien.html)
