As Europe advances towards a circular battery economy, the focus is shifting from simply collecting used batteries to recovering materials efficiently, safely and at scale, making recycling more than just an end-of-life activity. It is a critical part of resource security, sustainability and regulatory compliance.

Under Regulation (EU) 2023/1542, the EU Battery Regulation introduces strict requirements for traceability, material recovery and information sharing across the battery lifecycle. One important aspect is ensuring that recyclers and authorised operators have access to the information needed to dismantle batteries safely and effectively.

In this context, the concept of a “Dismantling Guide 2.0” is emerging, which embeds high-definition 3D disassembly instructions within the Digital Battery Passport (DBP), and the industry can significantly improve recycling efficiency, safety and material recovery outcomes.

Why Traditional Dismantling Information Falls Short

Battery packs, particularly those used in electric vehicles and industrial systems, are complex assemblies made up of modules, cells, cooling systems, electronics and structural components. These systems vary widely across manufacturers and designs.

Traditionally, dismantling information is provided in static formats such as PDFs, service manuals or internal documentation. These formats present several limitations:

• They are often difficult to interpret in high-risk environments.
• They may not reflect real-time design updates or variations.
• They lack interactive guidance for complex disassembly procedures.

In recycling environments, where speed and safety are critical, static instructions can increase the risk of errors, delays or accidents.

The EU Battery Regulation recognises the importance of providing detailed information for treatment and recycling, including safe handling and dismantling requirements.

What is The “Dismantling Guide 2.0”?

The “Dismantling Guide 2.0” refers to a new generation of interactive, digital disassembly instructions, delivered through the Digital Battery Passport. Instead of relying on static documents, recyclers can access high-definition 3D models, step-by-step visual guidance and contextual safety information linked directly to the battery’s digital identity.

These guides can include:

• Exploded 3D views of battery modules and components
• Interactive step-by-step disassembly sequences
• Identification of hazardous components, such as high-voltage connectors
• Real-time annotations for safe handling procedures
• Links to material composition data for targeted recovery

By embedding this information in the DBP, recyclers gain access to accurate, up-to-date guidance tailored to each specific battery model.

Enhancing Safety in Recycling Operations

Battery dismantling involves significant safety risks, including electrical hazards, thermal instability and exposure to hazardous materials. Incorrect handling can lead to short circuits, fires or chemical exposure.

The European Commission highlights that improving information availability is essential for safe battery handling and recycling as part of its circular economy strategy.

High-definition 3D instructions provide a clearer understanding of internal structures and risk points. Visual guidance can help operators identify safe disconnection points, avoid damaging sensitive components and follow correct procedures.

This reduces reliance on guesswork and improves consistency across recycling operations.

Improving Material Recovery Efficiency

Efficient dismantling is directly linked to material recovery rates. Batteries contain valuable materials such as lithium, cobalt, nickel and copper, which must be separated accurately to maximise recovery.

The EU Battery Regulation sets ambitious targets for material recovery and recycled content, reinforcing the need for precise and efficient recycling processes.

3D disassembly guides help recyclers:

• Locate specific components quickly
• Separate materials more effectively
• Reduce contamination between material streams
• Optimise processing time and labour costs

By improving dismantling accuracy, these tools contribute to higher recovery yields and better economic outcomes.

Supporting Automation and Advanced Recycling Technologies

As recycling volumes grow, the industry is moving towards automation and robotics. Automated dismantling systems require detailed, structured information about battery design and component layout.

Embedding 3D disassembly data within the Digital Battery Passport creates a foundation for machine-readable dismantling instructions. This enables integration with robotic systems and digital twins, supporting automated disassembly processes.

Research from the International Energy Agency highlights the importance of digitalisation in scaling battery recycling and improving resource efficiency.

By combining DBP data with advanced technologies, recyclers can move towards more scalable and efficient operations.

Interoperability and Data Standardisation

For 3D dismantling guides to be effective across the industry, they must be interoperable and standardised. The EU Battery Regulation emphasises that battery passport data must be machine-readable, interoperable and accessible to authorised stakeholders.

This requires:

• Standardised data formats for 3D models and annotations
• Consistent naming conventions for components and materials
• Integration with existing digital product passport frameworks

Ensuring interoperability allows recyclers, regardless of location or system, to access and use dismantling data effectively.

How BASE Can Enable Next-Generation Dismantling Through Digital Battery Passports

At BASE, we recognise that effective recycling depends on more than compliance. It requires actionable, high-quality data that supports real-world operations. Our Digital Battery Passport framework is designed to accommodate rich, structured data formats, including the integration of advanced disassembly information.

BASE supports interoperable data models, secure access mechanisms and lifecycle-linked information that can enable the inclusion of interactive dismantling guidance within the passport ecosystem. By connecting design data with end-of-life processes, BASE helps bridge the gap between manufacturing and recycling.

Through collaboration and pilot implementations, BASE is exploring how enhanced digital information can be integrated in the battery passport to improve safety, efficiency and circularity across the battery value chain.

Looking Ahead

The shift towards Digital Battery Passports is transforming how information flows across the battery lifecycle. Embedding high-definition 3D disassembly instructions represents the next step in making this data more actionable and valuable for recyclers.

As regulatory requirements tighten and recycling volumes increase, the ability to dismantle batteries safely and efficiently will become a competitive advantage. Organisations that invest in advanced digital guidance and interoperable data systems will be better positioned to meet regulatory targets, improve recovery rates and support a truly circular battery economy.

The BASE project has received funding from the Horizon Europe Framework Programme (HORIZON) Research and Innovation Actions under grant agreement No. 101157200.

References

EU Battery Regulation (Regulation (EU) 2023/1542): https://eur-lex.europa.eu/eli/reg/2023/1542/oj

EU Battery Regulation Detailed Text: https://eur-lex.europa.eu/eli/reg/2023/1542/2023-07-28/eng

European Commission – Circular Economy: https://environment.ec.europa.eu/topics/circular-economy_en

International Energy Agency – Global EV Outlook 2023: https://www.iea.org/reports/global-ev-outlook-2023