Integrating Eco‐Design Standards Into Assembly–Disassembly Requirements for Battery Pilot Line Processes

This study advances the sustainability of solid‐state batteries through eco‐design principles of life‐cycle integration. Emphasised solid polymer electrolytes as the primary case study, notably poly(vinylidene fluoride‐co‐hexafluoropropylene)‐based materials, which enhance intrinsic battery safety and enable a solvent‐free manufacturing option for advanced battery making. Scalable fabrication routes are investigated for both Ni‐rich cathodes and thin lithium metal anodes. Lithium metal on copper current collectors explored in this study is produced via thermal evaporation using the AVESTA advanced coating machine. Eco‐design strategies are implemented at the cell and module levels and conceptually extended to battery packs to promote modularity and facilitate further processing after end‐of‐life. A novel electricity‐induced adhesive debonding approach is introduced to enable non‐destructive disassembly of battery modules. Further, the safety‐oriented design choices, including reduced reliance on volatile solvents, support optimised recycling approaches. Manual, semi‐automated, and automated disassembly routes are assessed, with a hybrid strategy identified as the most effective balance between efficiency and recovery of precious metals. Environmental and techno‐economic analyses demonstrate reductions in emissions, waste generation, and operational costs. Aligned with European regulatory targets for 2030, this study provides practical disassembly protocols that support regulatory compliance and the recovery of critical raw materials, including lithium, cobalt, and nickel.