The EU-funded MARBEL project, coordinated by Catalonia’s Eurecat technology centre, has introduced a novel electric vehicle (EV) battery system that emphasizes modularity, ease of recycling, and innovations in ultra-fast charging. The new battery concept, developed with input from 16 partners across eight countries, seeks to improve sustainability and efficiency in EV battery design and performance.
Designed for quick assembly and disassembly, the MARBEL battery architecture integrates up to 60% recycled aluminium, helping reduce up to 777 kilograms of CO₂ emissions per battery pack. The modular structure facilitates component reuse, simplifies repairs, and extends battery lifespan. The battery’s cells are also engineered to support advanced recycling processes that enable the recovery of high-purity materials such as lithium, nickel, cobalt, manganese, and graphite from end-of-life cells.
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“The focus on circularity creates a pathway to more sustainable electric vehicle technology,” said Eduard Piqueras, MARBEL Project Coordinator and European Program Manager at Eurecat. “At the same time, by optimising battery performance, we address the main hurdles that hinder electric vehicles’ acceptance and adoption, such as limited range and lengthy charging times, enabling longer trips.”
The project’s developments include a new thermal management system for ultra-fast charging. This system ensures even heat dissipation across cells and busbars, paired with algorithm-based charging optimization. A switchable junction box enables seamless transitions between 400V and 800V, enhancing compatibility with multiple vehicle platforms.
In addition to its hardware innovations, MARBEL also introduced a custom battery management system (BMS). The design includes screw-fastened busbars for ease of assembly and durability, and a local intelligent Smart Cell Manager (iSCM) for each cell. This wireless Bluetooth-based communication setup reduces internal wiring dramatically—from over 20 meters to just 80 centimetres in a 16-cell pack—cutting down on weight, cost, and complexity.
“By integrating eco-design principles such as modularity, second-life applications, and materials with a high percentage of recycled content, MARBEL has extended battery usage while maintaining material value, effectively reducing waste and advancing both sustainability and economic viability,” added Violeta Vargas, researcher at Eurecat’s Waste, Energy, and Environmental Impact Unit.
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The MARBEL consortium includes research institutions such as SINTEF, Fraunhofer IWU, and the National Technical University of Athens, alongside companies like Stellantis – CRF, Applus IDIADA, FICOSA, AVL, and Powertech Systems.