In the early days, when cases were rare, simply replacing faulty packs with new ones and sending them to recycling was a workable solution. But as EV ownership increases, that approach becomes increasingly costly and environmentally unsustainable. To unlock the full environmental benefit of EVs, batteries need to remain in service for as long as possible. Premature replacement or recycling undermines that goal.
At the same time, misinformation around EV battery failure has fuelled unnecessary concern. It is essential to challenge these misconceptions with a clear, evidence-based view of how batteries can be repaired and restored to good condition. The long-term success of eMobility depends on it.
A common misconception is that recycling faulty EV batteries is the best route to sustainability. From a circular economy perspective, however, this view contradicts established scientific frameworks such as the waste hierarchy, which prioritises preventing waste in the first place.
For instance, producing an 82.5 kWh battery pack emits 11,600kg of CO2, with an additional 1,400kg generated during the recycling process, resulting in 13,000kg of carbon emissions per pack. In contrast, repairing a battery with a single remanufactured module emits only 951kg of CO₂, reducing emissions by 93% per restored pack, equivalent to offsetting over 12,000kg of carbon* (learn more in our recently published report). It is essential to maximise the service life of cells, modules, and packs wherever possible. When a fault occurs, the goal should be to identify the precise root cause and repair it in a targeted way, restoring the pack to optimal health. Many, if not most, battery faults can be addressed this way without resorting to recycling.
Another option is to harvest healthy modules from a failed pack and use them to repair others. By sacrificing one battery, several more can be kept in service for longer.
When compared to these approaches, the environmental return from prematurely recycling a faulty pack is far lower. Recycling still plays an important role, but it should be reserved for packs that are truly at end-of-life, not used as the default response.
It’s true that no EV battery can be restored to brand-new condition. From the first use, an irreversible chemical reaction begins, leading to gradual degradation over time, a process known as calendar ageing. This is normal for all types of batteries.
However, remanufacturing can significantly improve battery health. Cyclical deterioration, which results from how the vehicle is driven and charged, can be reversed. This restores performance to an optimal level and can be repeated at multiple points during the battery’s life, halting premature decline and maximising longevity. The EU Parliament’s first directive on EV batteries recognises this. It states that a remanufactured pack can be sold as such, provided its state of health has been restored to at least 90%.
For automakers, remanufacturing offers a viable alternative to the conventional “replace and recycle” approach. It is less costly, far less carbon-intensive, and prevents the waste of packs that are largely healthy, all while maintaining performance and reinforcing customer confidence.
In the past, many believed that EV batteries could not be reliably repaired. A single fault was seen as enough to render the entire pack obsolete, with replacement the only option.
With accurate testing, we now know that most failures are caused by a small group of underperforming cells or modules. By pinpointing the exact area of weakness, we can replace a faulty module with a healthy one and restore overall pack performance. With OptEVizer® providing a precise, cell-level picture of state of health, faults can be pinpointed with accuracy and addressed through targeted intervention via our REVIVE® EV battery servicing process.
This process is not simple, but with the right testing and repair capability it is entirely feasible. We know this from first-hand experience, having successfully restored thousands of batteries to optimal health.
Testing also plays a role beyond diagnosis. It allows us to identify healthy modules in other packs, which can be harvested and reused to restore additional batteries. Taken together, this proves that module replacement is both possible and practical with the right capability in place.
Repairing EV batteries does involve risks such as high voltages and the potential for thermal events, which has led some to assume it cannot be done safely.
Autocraft’s experience proves otherwise. Drawing on decades of remanufacturing expertise, we have built a scalable process that manages these risks effectively. Technologies like LiDAR and augmented reality guide technicians step by step through each repair, using a “no-fault-forward” system that prevents deviation from an optimal repair process.
Real-time checks ensure compliance with PPE and tool use, while facilities are equipped with early detection and fire suppression systems to contain any thermal events. Testing at the start of the process also identifies higher-risk batteries before work begins. All of these measures help to minimise the risk of hazards.
The result is a repair approach that is both safe and viable at industrial scale, showing that EV batteries can be repaired securely.
To move forward, the industry must challenge myths with evidence and science. Our work has shown that EV battery repair is not only possible, but can be done safely and at scale. With accurate, cell-level testing, faults can be identified and corrected, and healthy modules can be reused to restore other packs to full health.
This approach is more cost-effective than wholesale replacement, carries a far lower environmental footprint, and makes full use of the resources already in circulation. For EVs to deliver on their promise, repair and reuse must come before recycling, ensuring battery components stay in service for as long as possible. With REVIVE® and OptEVizer®, we’ve shown that this isn’t theory but proven practice, repair and remanufacturing can be carried out safely, at scale, and with measurable environmental benefit.
*Based on figures provided by members of the RECOVAS consortium
