Automated Laser Processing Enables Safer Recycling of EV Batteries
In the newly launched bilateral research project DigiBattCycle, LTB Lasertechnik Berlin (Division Laser-Microtechnology / LMT) is working alongside partners from research and industry on automated, digitally supported process chains for the remanufacturing and recycling of EV batteries. A central pillar of the project is the German-South Korean cooperation, aimed at leveraging technological synergies between both leading industrial hubs for a global circular battery economy.
Modern cell-to-pack architectures use high-strength thermosetting structural adhesives to ensure maximum operational safety and crash resistance. However, these irreversible polymer networks pose major challenges for end-of-life dismantling, as conventional mechanical or thermal separation methods carry the risk of cell damage or thermal runaway.
Within the project consortium, LTB focuses on automated laser-based processes to resolve this conflict between operational safety and recyclability. By applying short and ultrashort laser pulses, organic adhesive layers are removed through controlled photothermal and thermomechanical ablation (cold ablation). This process drastically minimizes the heat-affected zone and reliably protects temperature-sensitive battery cells from thermal stress.
The underlying process technology addresses two key steps in the battery lifecycle:
- Surface conditioning prior to joining: Laser-induced micro-structuring and chemical activation targetedly increase surface energy and optimize adhesion, eliminating the need for chemical pretreatments.
- Non-destructive separation: Integrated optical sensing and image processing automatically detect joint locations and enable layer-precise ablation for the pure-material separation of complex assemblies and electrical connections.
Combining optical analytics with micro-material processing expands LTB’s portfolio beyond individual laser processes toward holistic automation solutions for sustainable e-mobility.
About LTB Lasertechnik Berlin
LTB Lasertechnik Berlin develops and produces laser processes, laser systems, and complete automation systems. These machines have proven themselves in a wide variety of locations: from clean rooms at pharmaceutical companies and research laboratories to production halls in the metalworking industry.
These products include:
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