UK’s Altilium Achieves Breakthrough in EV Battery Cell Production Using Recycled Materials

UK-based clean technology firm Altilium has successfully completed large-scale electric vehicle (EV) battery cell manufacturing trials using recycled cathode materials, with results demonstrating performance nearly identical to that of cells made from conventionally mined components.

The pilot, conducted at the UK Battery Industrialisation Centre (UKBIC) in Coventry, utilized Altilium’s proprietary EcoCathode NMC 811-2036 cathode active material (CAM), which was recovered from end-of-life EV batteries at its Devon site. The results support the feasibility of industrial-scale battery circularity and the creation of a localized battery materials supply chain in the United Kingdom.

“These results mark a pivotal moment for battery circularity in the UK,” said Dr Christian Marston, co-founder and COO of Altilium. “For the first time, we’ve demonstrated that battery-grade EV cells can be manufactured at scale using recycled materials – with no compromise on quality or manufacturability.”

The recycled CAM achieved recovery rates exceeding 95% for lithium, nickel and cobalt. Electrochemical testing showed less than 1% variation in key performance indicators such as energy density, impedance, first cycle loss, and early-stage cycling behaviour compared to benchmark commercial materials. Furthermore, the materials were shown to integrate seamlessly with existing battery manufacturing processes including slurry mixing, electrode coating, and cell assembly, requiring no major adjustments to production lines.

UKBIC Chief Technology Officer Richard LeCain noted, “This groundbreaking project marks the beginning of a journey that could reduce the UK’s dependence on imported materials and open up a new market for recycled batteries.”

The battery cells are now undergoing validation with a major automotive manufacturer, aligning with upcoming EU Battery Regulations that mandate minimum recycled content levels in EV batteries. Altilium is also expanding its operations with the launch of its ACT 2 recycling facility in Plymouth and the forthcoming ACT 3 site, which will recover battery materials from up to 24,000 EVs annually.