U.S Department of Energy

Powering a Circular U.S. Battery Economy Through Research, Funding, and Industry Partnerships

The U.S. Department of Energy (DOE) accelerates safe, efficient, circular management of EV batteries—linking research with funding and partnerships. DOE helps automakers, recyclers, and battery manufacturers recover more value, cut environmental impact, and strengthen domestic supply chains.

What DOE Brings to EV Battery Recycling:

• National R&D leadership: ReCell and the national labs advance direct recycling, design-for-disassembly, and low-emissions processes that raise material yields and quality.

• Market-scale funding: Competitive grants expand U.S. capacity for materials processing, manufacturing, and recycling, de-risking first-of-a-kind facilities.

• Prizes that unlock collection: The Lithium-Ion Battery Recycling Prize catalyzes new models for collection, logistics, and safe handling.

• Catalytic financing: The Loan Programs Office provides long-tenor financing to scale strategic recycling and materials projects.

• Supply-chain coordination: Li-Bridge aligns industry and government on standards, permitting, and action plans for a resilient circular ecosystem.

• Workforce and standards: National guidelines and training support safe operations, compliance, and high-quality jobs across the battery lifecycle.

DOE lowers cost and risk at end of life, boosts domestic recovery of critical minerals, and supports U.S. jobs—making EVs more sustainable and supply chains more secure nationwide. By coupling early-stage innovation with commercialization and deployment, DOE turns lab breakthroughs into field-tested solutions. The result: more batteries safely collected, disassembled, reused, and recycled; fewer transport emissions; and greater traceability from pack to precursor. DOE is building the backbone of America’s circular battery economy—so stakeholders can scale faster, comply confidently, and keep valuable materials in the loop.

ElectraMet

Advancing High-Purity Metal Recovery for EV Battery Recycling

ElectraMet is redefining EV battery recycling economics with a highly selective electrochemical platform that removes copper, manganese, and other trace metals from lithium, nickel, and cobalt streams—meeting battery-grade specifications while protecting product yield. Unlike sulfide precipitation, ion exchange, or membranes, ElectraMet can extract impurities in a single pass, minimizing rework, yield loss, and byproducts. 

At the core is carbon-electrode technology that actively captures dissolved metals as pure, saleable solids—operating with exceptional selectivity, no sludge generation, and dramatic reductions in operating costs versus chemical methods. Real-time online diagnostics confirm performance, enabling recyclers to focus on throughput while consistently hitting purity targets for black mass leachates, pCAM production, and sulfate polishing. 

Impurity Polishing
Electrochemically targets trace Cu, Mn, Ni, and Co to preserve high-value Li/Ni/Co products and improve downstream crystallization quality. 

Metal Valorization
Recovers copper as a pure metal product, creating a new revenue stream rather than a waste stream.

Chemical-Lean, Sludge-Free Operation
Delivers 99%-selective capture with no sludge and up to 90% OpEx reduction—improving compliance and eliminating hauling. 

In-Line Control & Traceability
Built-in monitoring provides continuous verification of removal and recovery performance. 

Black Mass & pCAM Readiness
Designed to meet ultra-low impurity thresholds required for battery-grade precursors and recycled sulfates.

As North America scales a circular battery economy, ElectraMet gives recyclers and cathode producers a compact, drop-in route to higher yields, lower chemical intensity, and verified product quality—keeping critical minerals in the loop and waste out of it. 

SkyTerra Group

Operations Intelligence and Compliance for Next-Gen EV Battery Facilities

SkyTerra Group equips recyclers, OEMs, and battery manufacturers with the technical depth and automation needed to scale safe, circular EV battery systems—faster, leaner, and with confidence. Formerly Scharf Energy, the company now operates as SkyTerra Group, reflecting a broader mission that spans engineering, AI, and commercialization for the clean-energy value chain. 

At the heart of SkyTerra’s offering is a fusion of AI automation, advanced engineering, and energy expertise—applied from grid batteries and solar-storage plants to rapid EV-charging hubs. The team delivers BESS architecture, vendor audits, and certification roadmaps, including UL9540, UL1973, and UN 38.3 test planning—so projects are designed for safety, compliance, and bankability from day one. 

Battery Systems & Certification
BESS sizing, pack design readiness, compliance gap analyses, and on-site safety audits de-risk pre-treatment, second-life, and recycling projects. 

AI-Driven Operations
EMS/BMS/SCADA optimization, predictive analytics, and digital twins enhance throughput, reliability, and traceability across collection, disassembly, and processing. 

Site & Infrastructure
Microgrid management, black-start/UPS design, and EV charging development connect recycling facilities to resilient, cost-optimized power. 

Market & Investment
Owner’s representation, technical due diligence, and partner scorecards align stakeholders and capital with the right technologies at the right stage. 

Materials & Product Development
Failure analysis, materials selection, and performance validation support durable equipment, safer packs, and smoother certification. 

As North America builds a circular EV battery ecosystem, SkyTerra provides plug-in technical leadership and automation that reduce risk and OpEx, improve safety and data integrity, and accelerate commercialization—keeping critical materials in the loop and projects on track. 

Princeton NuEnergy

Plasma-Enabled Direct Recycling for Cleaner, Battery-Grade Recovery

Princeton NuEnergy (PNE) is transforming EV battery circularity with LPAS™—a low-temperature, plasma-assisted direct recycling process that rejuvenates cathode and anode materials while sharply reducing energy, chemicals, and cost. By repairing rather than dissolving, PNE preserves material value and accelerates the path back to battery-grade products.

At the heart of PNE’s offering is selective plasma treatment and gentle purification that remove binders, contaminants, and degradation layers, enabling cathode-to-cathode regeneration with a far lower footprint than hydromet or pyro routes. Independent reporting notes up to 95% material recovery and roughly 70% lower energy use. Founded in 2019 out of Princeton University, PNE pairs breakthrough science with scaled operations. 

Operational Scale
A newly commissioned facility in Chester, South Carolina processes 5,000 tpy of manufacturing scrap into “Advanced Black Mass,” building domestic capacity for high-purity, battery-ready feedstocks. 

Battery-Grade Rejuvenation
LPAS™ restores NCM and LFP material performance, supporting direct re-entry into precursor/cathode production instead of down-cycling. 

Chemical-Lean, Carbon-Light
Minimal reagents, no high-temperature furnaces, and sharply reduced waste generation versus conventional methods. 

Quality & Traceability
Process controls deliver consistent purity for downstream crystallization and cell manufacturing. 

Origin & Expertise
A Princeton-born venture advancing direct recycling science into commercial reality. 

As North America scales EV battery recycling, PNE provides a faster, cleaner route to high-value materials—boosting yields, cutting OpEx and emissions, and keeping critical minerals in the loop for next-generation mobility.

Archimedes Industrial Advisory & Investment

Safety-First Equipment, Sourcing, and Scale-Up for Circular EV Battery Operations

Archimedes Industrial Advisory & Investments (AIAI) equips recyclers, OEMs, and battery manufacturers to launch and optimize safe, circular facilities—bridging hands-on engineering, materials sourcing, and investment insight. The team’s executives and engineers bring deep experience in feedstock logistics, processing-line design, waste management, and material recovery—translating strategy into operating assets. 

At the heart of AIAI’s offering is pragmatic, on-the-floor execution. In partnership with Gloyd Recycling Solutions, AIAI helped develop and commercialize the BIDS23 Battery-In-Device-Shredder: a compact, warehouse-ready system that reduces thermal-incident risk and separates plastic, metal, and black mass with a wet-scrubbed, zero-emissions configuration. 

What AIAI Brings to EV Battery Recycling

• Battery-in-Device Processing: Plug-and-play shredding and safe pre-treatment for devices containing lithium-ion cells—cutting downtime and manual handling.
  

• Material Sourcing & Offtake: Reliable flows of primary/secondary non-ferrous materials and by-products, tailored to operational needs.
  

• Plant Design & Commissioning: Production-line design, cold/hot commissioning, and owner’s-rep support to hit throughput and quality targets.
  

• Hazardous Waste & Metals Recycling Solutions: Practical upgrades that improve recovery, emissions, and safety across pre-treatment and hydromet.
  

• Investment & Scale-Up: A boutique fund targeting sub-$10M industrial operations in metals/chemicals—aligning technology choices with bankable economics. 

As North America scales a circular battery economy, AIAI delivers the blend of equipment innovation, sourcing, and industrial know-how required to de-risk projects, raise yields, and keep critical materials in the loop—so facilities move from plan to production faster, safer, and with confidence.

EcoX Energy Inc.

Next-Generation LFP Cathodes for Cleaner, Cost-Optimized EV Circularity

EcoX Energy Inc. is advancing the EV battery ecosystem with high-purity, U.S.-market LFP cathode materials engineered for performance, sustainability, and scale. By delivering battery-grade LFP at lower cost and with a lighter footprint, EcoX helps recyclers, cell makers, and OEMs keep critical minerals in the loop and accelerate domestic manufacturing. 

At the heart of EcoX’s offering is its EcoX TriMET technology—an integrated flow that combines advanced hydro, pyro, and powder-metallurgy techniques to unite eco-friendly operation with cost efficiency. Production targets include 40% lower cost, 30%+ energy savings, 30%+ carbon-emission reductions, and 99.9%+ product purity, supported by automation to reduce labor needs. Headquartered in Houston, the company was founded in 2025 to supply economical, high-performance LFP to the U.S. market. 

Battery-Grade LFP Portfolio
Tailored cathode lines for energy storage, mainstream EVs, and high-performance EV applications, plus custom formulations for specialized needs. 

Sustainable, Efficient Production
Process design aims for 40% lower production cost, 30%+ energy and carbon reductions, and 99.9%+ purity to meet stringent cell-maker specs. 

Automation for Quality & Throughput
Higher automation lowers labor by ~30% while supporting consistent quality, traceability, and repeatability at scale. 

U.S. Presence, Circular Focus
With a Houston base and a mission centered on economical, sustainable LFP, EcoX aligns with recyclers and precursor producers to valorize recovered materials into new cathode product. 

As North America builds a resilient, circular battery supply chain, EcoX provides a cost-effective, low-impact LFP pathway—supporting safer, cleaner, and more reliable EV manufacturing and end-of-life recovery.

Battery Metals, Inc.

High-Yield, Clean-Process Recovery for Circular EV Batteries

Battery Metals, Inc. is advancing the EV battery ecosystem with high-efficiency recovery of critical minerals from end-of-life lithium-ion batteries and manufacturing scrap—helping recyclers and cell makers turn waste into battery-grade supply. The company buys consumer batteries, OEM scrap, and end-of-life EV packs, creating dependable feedstock for circular production. 

At the heart of Battery Metals’ offering is a North Carolina campus engineered for industrial scale: integrated shredding and refining capacity of 26.5 million pounds per year. Their advanced process avoids furnace incineration and is built to recover over 98% of critical minerals at lower cost—producing IRA-compliant materials for the domestic market. The company is also developing R2/RIOS certification to strengthen traceability. 

Clean Pre-Processing
Modern mechanical pre-treatment that eliminates furnace pollution pathways and protects material value for downstream refining. 

High-Recovery Refining
Process designed for >98% recovery of lithium, nickel, cobalt, manganese, and copper.

Scrap Sourcing & Logistics
Active purchasing from consumer streams, OEM scrap, and end-of-life EV batteries to secure consistent, domestic inputs. 

Compliance & Certification
R2/RIOS program in development to align operations with rigorous environmental and safety standards. 

Domestic Supply Chain Impact
IRA-compliant materials and a North Carolina base support U.S. manufacturers with reliable, lower-footprint critical minerals. 

As North America scales EV battery recycling, Battery Metals provides a clean, cost-optimized route to high-value recovery—keeping critical minerals in the loop and enabling safer, smarter, and more circular mobility.

Aepnus Technology

On-Site Electrochemical Reagent Regeneration for Cleaner, Circular Battery Supply Chains

Aepnus Technology transforms a stubborn bottleneck in the EV battery lifecycle—sodium sulfate waste—into the very reagents recyclers and cathode makers rely on. Using a breakthrough salt-splitting process, Aepnus converts sodium sulfate brines into high-purity caustic soda (NaOH) and sulfuric acid (H₂SO₄), cutting disposal, reducing trucked chemicals, and hardening domestic supply chains. 

At the heart of Aepnus’ offering is a patented electrolyzer engineered for industrial impact: low cell voltage, high current density, and robust operation on real-world waste streams—without rare, expensive catalysts. Deployed as on-site units, the system generates NaOH and H₂SO₄ independent of chlorine markets, with active pilots from Oakland to Bécancour, where partners include Ultium CAM (GM x POSCO), Vale, and Nemaska Lithium.

Sodium Sulfate Circularity
Regenerate battery-grade NaOH/H₂SO₄ directly from sodium sulfate, closing the loop for recyclers, refiners, and CAM producers while tackling a rapidly growing waste challenge. 

On-Site, Modular Deployment
Produce critical reagents where they’re used to streamline logistics, improve traceability, and reduce permitting and waste-handling risk. 

Production-Grade Performance
Thousands of continuous operating hours and higher energy efficiency than conventional electrolysis deliver dependable throughput and lower OpEx for battery facilities. 

Ready for Scale
Aepnus is progressing a demonstration plant (>500 t/yr sodium sulfate) and customer pilots across North America to de-risk commercial rollouts. 

As automated, low-impact recycling becomes essential to North America’s circular battery economy, Aepnus provides a practical, regulation-ready path: turn waste into reagents, shrink transport and emissions, and stabilize costs—so recyclers, OEMs, and material producers can scale faster and more sustainably.

Green Li-ion

Modular Black-Mass-to-Battery-Grade Upcycling for Localized Circularity

Green Li-ion is reshaping EV battery recycling with modular GLMC™ systems that upcycle black mass directly into high-value outputs—precursor cathode active material (pCAM), graphite, and technical-grade lithium carbonate—cutting steps, cost, and emissions across the supply chain. Built for colocated deployment at recyclers and gigafactories, Green Li-ion enables on-site, closed-loop recovery that feeds straight back into new cell production. 

At the heart of the offering is GREEN HYDROREJUVENATION™, a hydromet process tuned for speed and purity. The platform converts unsorted black mass into battery-ready pCAM with 99%+ purity—without third-party refiners—and can synthesize multiple chemistries, supporting NMC and other cathode families in one skid. Recent deployments include North America’s first commercial-scale black-mass-to-pCAM installation, launched in April 2024 within an existing recycling facility. 

Direct Upcycling
Skip intermediate shipments: move from shredded feedstock to pCAM, graphite, and lithium salts in a compact, modular line. 

Multi-Cathode Capability
Produce engineered pCAM for multiple chemistries with a single, closed-loop system—enhancing flexibility and asset utilization. 

Speed & Footprint
Process black mass to pCAM in under 12 hours with lower energy intensity than conventional routes, enabling localized, lower-carbon supply. 

Quality & Traceability
Integrated controls and purification deliver battery-grade specs suitable for cathode production and reintegration into domestic manufacturing. 

As EV volumes rise, Green Li-ion’s drop-in plants give recyclers, cathode producers, and OEMs a faster, cleaner path to circularity—turning today’s end-of-life batteries into tomorrow’s materials while strengthening resilient, North American supply chains.

Currents

Trusted Marketplace, Diagnostics, and Automated Sourcing for Circular EV Batteries

Currents is transforming end-of-life EV battery commerce with a trusted B2B marketplace and built-in identification and diagnostics—so batteries move to reuse, remanufacture, or recycling with transparency and safety. Buyers can filter inventory by state-of-health, chemistry, and price, and access exclusive OEM stock as the official marketplace for Nissan North America 4R. The result is faster sourcing from one of North America’s largest supplier networks. 

At the heart of Currents’ offering is a unified toolset: Marketplace™ for transaction transparency; Insight Certified™ (powered by Midtronics) for battery safety and SOH verification; Insight LookUp™ for instant VIN-based identification and valuation; and Buying Programs for automated, criteria-driven procurement. 

Marketplace & OEM Access
Search, compare, and purchase with confidence—including exclusive OEM inventory via Nissan 4R. 

Insight Certified™ Safety & SOH
Touch-safety checks (Midtronics xVT) and SOH diagnostics (xOBD-200) auto-sync to listings, giving buyers certified test data. 

Insight LookUp™ & Valuation
Identify batteries by VIN or year/make/model; see chemistry, estimated market and recycling value, and DOT classification; bulk-upload inventory with Inventory by Insight™. 

Automated Buying Programs
Set specs, quantities, and price tiers; Purchase Orders auto-execute when matches appear, or use Watchlists for notifications—useful as EPR obligations expand. 

Bulk Recycling & Logistics
Fill truckloads with chemistry-homogeneous lots and leverage Currents’ logistics tools for compliant, hassle-free shipping. 

As EV volumes rise, Currents equips recyclers, OEMs, and second-life integrators to de-risk safety and quality, cut sourcing time and cost, and keep critical materials in the loop—enabling a more efficient, circular battery economy.

XEra Energy

Hydro-Separation & Closed-Loop Cathode Materials for Cleaner, U.S. Circularity

XEra Energy is reshaping EV battery recycling with a hydro-separation and purification platform that recovers critical minerals—nickel and lithium—from black mass and concentrates, then upgrades them toward closed-loop cathode materials. By localizing high-value refining, XEra helps recyclers, cathode producers, and OEMs turn waste and variable feedstocks into reliable, battery-ready supply while strengthening domestic manufacturing. 

At the heart of XEra’s offering is process engineering that fuses selective wet-chemistry separation with purification steps tuned for battery applications. Headquartered in San Francisco and scaling with HAX in Newark, the company was founded in 2024 and is positioning to serve North American gigafactories with flexible, chemistry-agnostic recovery and upgrading. XEra is led by CEO Dr. Haixia (Casey) Deng, formerly VP of Cathode at Ascend Elements. 

Hydro-Separation & Purification
Selective wet processes that raise recovery and simplify downstream crystallization and cathode synthesis. 

Black-Mass Upgrading
Convert diverse chemistries into consistent, high-purity intermediates ready for precursor/cathode production. 

Plant-Ready Integration
Process train designed to integrate with shredding and hydromet sites—reducing transport steps and lead times. 

Domestic Supply-Chain Impact
Closed-loop materials support U.S. manufacturing resilience while reducing exposure to overseas refining.

Execution & Expertise
Founder-led, industry-tested leadership translates chemistry into plant-ready flowsheets for scale. 

As EV volumes rise, XEra Energy gives recyclers and manufacturers a pragmatic path to circularity—recovering more value from every pack and returning it to the road as new, high-quality battery materials.

Ascend Elements

Direct Upcycling to Battery-Grade pCAM for Safer, Smarter, and More Circular Recycling

Ascend Elements transforms end-of-life EV batteries into high-value materials with Hydro-to-Cathode®—a patented direct-synthesis process that upcycles black mass into engineered precursor cathode active material (pCAM). By leaching impurities (not value), Ascend Elements shortens the recycling flow, preserves metals in solution, and delivers battery-grade outputs with lower cost and carbon. 

At the heart of the offering is a closed-loop platform that connects industrial pre-treatment with advanced materials manufacturing. Base 1 in Covington, Georgia—one of North America’s largest LIB recycling facilities—can intake ~30,000 metric tons per year of end-of-life packs and manufacturing scrap, producing high-quality intermediates for reintegration.

Hydro-to-Cathode® Direct pCAM
Ascend Elements’ direct pCAM synthesis tunes microstructure to customer specs, enabling high performance while avoiding multiple refining steps common in traditional hydro/pyro routes. A recent study shows up to ~49% lower CO2e than conventional recycling methods. 

Domestic Materials at Scale
The planned Apex 1 campus in Hopkinsville, Kentucky will onshore pCAM manufacturing in a >1-million-sq-ft facility supported by an active $316M U.S. DOE grant—strengthening North American supply resilience. 

Safety, Compliance, and Traceability
From DOT-compliant logistics to controlled purification and quality assurance, Ascend Elements helps OEMs, recyclers, and cathode producers meet tight specifications with audit-ready documentation. 

As automated recycling becomes essential to scaling the EV transition, Ascend Elements’ direct-upcycling platform turns today’s packs into tomorrow’s cathode materials—reducing transport, emissions, and cost while keeping critical minerals circulating in the domestic battery economy.

Ford Motor Company

OEM-Led Circularity and Closed-Loop Battery Materials for Safer, Smarter EV Recycling

Ford Motor Company is building a circular EV battery ecosystem—pairing large-scale manufacturing with end-of-life collection and materials recovery. Through its strategic relationship with Redwood Materials, Ford is developing closed-loop pathways so lithium, nickel, cobalt, and copper from used packs and production scrap re-enter new batteries, strengthening a domestic supply chain and lowering environmental impact. 

At the heart of Ford’s approach is integration: BlueOval City is designed with zero-waste-to-landfill processes and on-site materials collection to route production scrap for recycling, while Redwood’s program with initial partners Ford and Volvo pilots dealer and dismantler recovery of end-of-life packs—creating real, traceable flows from vehicle to new battery materials. 

Closed-Loop Partnerships
Redwood collaboration targets a sustainable, U.S. battery materials supply through recycling and remanufacturing. 

Manufacturing Scrap to Materials
Production scrap from Ford’s battery operations is captured and routed for recovery, supporting new cathode and copper products. 

Dealer-to-Recycler Pathways
California pilot creates standardized, safe logistics from dealers/dismantlers to Redwood facilities, expanding end-of-life collection. 

Plant-Integrated Circularity
BlueOval City’s collection center and water-reuse systems embed recycling and resource efficiency into vehicle assembly. 

Traceability & Scale
Partnerships emphasize verified recovery rates and reintegration of critical minerals into new cells—supporting resilient North American manufacturing.

As automated, regulation-ready recycling becomes essential to EV scale-up, Ford’s OEM-led circularity connects design, production, and end-of-life recovery—reducing cost and emissions while keeping valuable materials in the loop for the next generation of electric mobility. 

Capgemini

Data-Driven Traceability, AI, and Gigafactory Scale-Up for a Circular EV Battery Economy

Capgemini equips OEMs, recyclers, and battery manufacturers to build safe, regulation-ready circularity—connecting product traceability with intelligent manufacturing at gigafactory scale. From Digital Battery Passports to plant-level analytics, Capgemini helps stakeholders recover more value from end-of-life packs and production scrap while meeting fast-approaching compliance milestones. 

At the heart of Capgemini’s offering is its Intelligent Industry approach: uniting engineering, cloud, data, and AI to design, ramp, and optimize battery facilities from pilot line to full production. The team supports line virtualization, MES/MOM integration, and quality analytics—so circular processes are designed in, not bolted on. Capgemini also plays a sector-shaping role in Europe’s battery ecosystem and helps clients accelerate the journey to the “gigafactory of the future.” 

Digital Battery Passport & Traceability
Blueprint and deploy DPP/DBP solutions that consolidate lifecycle data for repair, reuse, and recycling—and satisfy EU requirements starting February 18, 2027. 

Intelligent Manufacturing for Circularity
Integrate digital twins, automation, and analytics to boost yield, energy efficiency, and material recovery across pre-treatment and cell/cathode lines. 

Gigafactory Design & Ramp-Up
End-to-end support from strategy and R&D to commissioning and scale, including the Technology Cluster Battery Cell and partner ecosystem. 

AI, Cloud & Data at Scale
Apply market-leading AI, generative AI, and data platforms for predictive maintenance, scrap reduction, and compliant reporting. 

As EV volumes surge, Capgemini helps the industry embed circularity by design—enabling verifiable recovery, lower carbon and cost, and resilient, local battery supply chains that keep critical materials in the loop.

KULR Technology Group

Thermal-Runaway Protection & Safe Logistics for Safer, Smarter Circular EV Recycling

KULR Technology Group is transforming safety and efficiency across the EV battery lifecycle—pairing NASA-proven thermal management with packaging, testing, and logistics that move packs to reuse or recycling with confidence. From cell characterization to compliant transport, KULR helps OEMs, recyclers, and integrators cut incident risk, lower cost, and keep critical materials in the loop. 

At the heart of KULR’s offering is its patented Thermal Runaway Shield™ (TRS) and SafeCASE™. TRS is a passive propagation-resistant layer that prevents cell-to-cell thermal runaway, while SafeCASE provides DOT-permitted, ground-transport containers (up to 2.5 kWh per case) for damaged, defective, or recalled lithium-ion batteries—complete with training and documentation for UN 38.3–eligible shipments. KULR backs this with battery testing and abuse diagnostics for modules and packs. 

Thermal Runaway Mitigation
TRS integrates into packs to stop propagation and protect people, equipment, and facilities during storage, handling, and pre-treatment. 

Certified Storage & Transport
SafeCASE enables compliant, warehouse-to-recycler moves under PHMSA special permits, reducing fire risk and downtime while standardizing DDR logistics.

Battery Testing & Verification
Cell and module cycling, abuse testing, and analysis verify performance and safety—supporting UN 38.3 readiness and quality assurance. 

Recycling Partnerships
KULR partners with Cirba Solutions on a national program that combines SafeCASE with logistics and processing for end-of-life and prototype batteries. 

As automated recycling scales, KULR’s safety-first platform prevents propagation, standardizes compliant shipping, and equips recyclers to operate faster, safer, and more sustainably.

TerraCycle

Compliant Collection, Tracking, and Logistics for Safer, Smarter Circular Battery Flows

TerraCycle streamlines the messy middle of EV battery circularity—collection, packaging, and transport—so recyclers, dealers, fleets, and service centers can move batteries and battery-containing devices into reuse, remanufacture, or recycling with confidence. Its TerraCycle Regulated Waste (TCRW) division delivers mail-back and bulk pickup services that standardize safety and documentation across the U.S. 

At the heart of TerraCycle’s offering are UN-certified EasyPak™ Battery Buckets with prepaid return labels, online container tracking, and certificates of recycling—plus nationwide bulk pickups for higher volumes. This gives operators a right-sized pathway from a few boxes to truckload quantities without sacrificing compliance or data integrity. 

Compliant, Ready-to-Ship Packaging
UN-certified containers include terminal-taping supplies and instructions; workflows align to PHMSA/DOT lithium-battery transport requirements (HMR; UN 38.3 context). 

Flexible Collection Models
Use EasyPak™ mail-back for smaller volumes or schedule bulk pickups for facilities with steady streams of batteries and e-waste. 

Traceability & Reporting
Container tracking and recycling certificates support audit-ready ESG reporting and internal compliance records. 

Brand & OEM Programs
TerraCycle also runs take-back programs for products with non-removable lithium-ion batteries—demonstrating expertise in safely handling embedded cells at scale. 

Hard-to-Recycle Leadership
Backed by a global platform dedicated to “Eliminating the Idea of Waste®,” TerraCycle brings proven logistics and recovery know-how to battery end-of-life. 

As EV volumes rise, TerraCycle provides the regulation-ready logistics backbone that reduces risk and cost, accelerates collection, and keeps valuable materials flowing to certified recyclers—fueling a safer, smarter, more circular battery economy.

H.B. Fuller

Debond-on-Demand Adhesives and Thermal Protection for Safer, Smarter, More Circular EV Batteries

H.B. Fuller is accelerating EV battery circularity with adhesive and encapsulant systems that make packs safer to build, easier to service, and simpler to disassemble at end of life. From debond-on-demand concepts that enable controlled separation to flame-retardant encapsulants that help arrest thermal propagation, H.B. Fuller equips OEMs, recyclers, and pack integrators to recover more value with less risk. 

At the heart of the offering is a portfolio tuned for the full pack lifecycle: EV Protect™ polyurethane encapsulants for propagation mitigation; EV Seal™ resealable pack gaskets for serviceability; and EV Bond™ structural and thermally conductive adhesives for robust assembly and heat pathways—supported by application engineering for gigafactory integration. 

Debonding & serviceability
Resealable, repair-friendly sealing strategies allow packs to be opened for module replacement, reuse, or recycling—advancing circular design without sacrificing protection in use. 

Thermal propagation mitigation
EV Protect™ 300/4006/5008 encapsulants help isolate events, insulate adjacent cells, and minimize propagation, with lightweight foams that also support energy density. 

Structural bonding & heat management
Battery-grade adhesives (including thermally conductive grades) secure cells, lids, and cooling hardware, improving durability and thermal pathways for safer operation.

Process integration at scale
H.B. Fuller supports line design, materials selection, and quality control for EV programs—from pilot to plant—so safety, serviceability, and circularity are built in from day one. 

As automated recycling and repairability become essential, H.B. Fuller’s battery solutions align manufacturing performance with end-of-life outcomes—reducing incident risk and enabling verified recovery that keeps critical materials in the loop.

Lucid Motors

OEM-Led Second Life & Circular Materials Pathways for Safer, Smarter EV Batteries

Lucid Motors is building a circular battery ecosystem that starts with ultra-efficient vehicles and extends through reuse and responsible end-of-life flows. By pairing a 924-volt architecture with industry-leading efficiency, Lucid reduces material per mile while enabling faster charging and lower operating emissions—design choices that lighten the load on recycling systems downstream. 

At the heart of Lucid’s approach is integration across the lifecycle: production and test batteries are already recycled, and the company is developing end-of-life strategies for traction packs as field volumes grow. 

Second-Life Energy Storage
Lucid has engineered its packs for a “two-life” journey, prototyping stationary systems (≈300 kWh) that redeploy healthy modules before eventual materials recovery. 

Domestic Materials Alliances
Through the new MINAC collaboration—including partners such as RecycLiCo, Graphite One, and Alaska Energy Metals—Lucid is helping strengthen U.S. supply chains for battery-critical minerals that feed recycling and remanufacturing loops. 

Vehicle-to-Everything Readiness
Bi-directional capability underpins grid and facility backup use cases, complementing second-life pathways and improving total pack productivity over time. 

Efficiency as Circularity
Lucid’s high-voltage, power-dense platform delivers long range with fewer cells—reducing upstream mineral demand and downstream waste while keeping performance uncompromised. 

As automated recycling scales across North America, Lucid’s lifecycle strategy—designing for efficiency, enabling second-life deployments, and supporting domestic materials initiatives—helps recyclers, utilities, and OEM partners recover more value, cut emissions, and keep critical minerals circulating for the next generation of electric mobility.

American Battery Technology Company

Closed-Loop Hydromet Upcycling for Battery-Grade Materials in the U.S. Scale

American Battery Technology Company (ABTC) is building a circular EV battery ecosystem—turning end-of-life packs and manufacturing scrap into high-value materials while onshoring critical mineral supply. As a first-mover in integrated recycling and primary lithium extraction, ABTC helps OEMs, recyclers, and cell makers reduce cost, emissions, and risk across the battery lifecycle. 

At the heart of ABTC’s offering is a closed-loop “de-manufacturing” and hydrometallurgical process that avoids high-temperature furnaces, safely separates metals, and refines them for reintegration into new batteries. This chemistry-forward approach improves recovery efficiency and product quality for downstream cathode production.

Commercial Recycling
ABTC operates a commercial facility in the Tahoe Reno Industrial Center (TRIC), scaling mechanical pre-treatment and hydromet refining; the company reported production increases in 2025 as it expanded output. 

Domestic Black-Mass Sales
ABTC executed a bulk sale of high-nickel, high-cobalt recycled black mass to a U.S. strategic customer—advancing closed-loop materials flows for North American manufacturing. 

Battery-Grade Pathways
The platform produces intermediary materials for battery re-entry and is designed to upgrade to battery-grade outputs, supporting resilient, IRA-aligned domestic supply chains. 

Integrated Primary Lithium
Beyond recycling, ABTC’s Tonopah Flats project and Nevada demonstration facility manufacture lithium hydroxide from claystone—complementing recycled streams with new domestic supply in a single ecosystem. 

Why it matters: As automated, regulation-ready recycling becomes essential to EV scale-up, ABTC provides the chemistry, capacity, and U.S. footprint to keep critical minerals in the loop—accelerating recovery, lowering environmental impact, and strengthening domestic battery manufacturing for the next generation of electric mobility. 

ReJoule

Fast, Non-Invasive Battery Grading for Safer, Smarter, and More Circular Recycling

ReJoule is transforming EV battery circularity with rapid, non-invasive diagnostics that route packs and modules to the highest-value outcome—reuse, remanufacture, or recycling. Using electrochemical impedance spectroscopy (EIS), ReJoule’s BattScan™ platform measures state-of-health (SOH) in minutes (not hours), enabling stakeholders to recover more value with less risk and downtime.

At the heart of ReJoule’s offering is its portable BattScan hardware family and BatteryDB™ cloud, which bring lab-grade precision to warehouses and dismantling sites. BattScan tests cells, modules, and full packs; the 500V model can evaluate packs directly through a vehicle’s DC fast-charge port—reducing handling and accelerating triage. 

Fast, Accurate Diagnostics
Ten-minute tests with benchmarked capacity estimation accuracy and rich EIS insights inform reuse vs. recycle decisions and pricing. 

Throughput & Traceability
Field case studies demonstrate up to 45 modules/day per unit, with results synced to BatteryDB for audit-ready records and logistics planning. 

Pack-Level, Non-Invasive Testing
Evaluate high-voltage packs via the charge port, minimizing disassembly, safety risk, and labor. 

Second-Life Enablement
ReJoule leads DOE’s OCED CARES demonstrations to repurpose retired EV batteries into community energy storage—showcasing circular value before recycling. 

Award-Winning Innovation
ReJoule is a DOE Re-X Before Recycling Prize semifinalist for solutions that extend product life and improve circular flows. 

As automated recycling scales, ReJoule’s diagnostics platform gives OEMs, recyclers, and repurposers a plug-and-play path to speed intake, standardize grading, and de-risk operations—so more usable batteries power a verified second life, and the rest reach recyclers with precise data and safer handling.

ONE | Our Next Energy

LFP Platforms, U.S. Manufacturing, and Grid Systems for Safer, Smarter Circularity

Our Next Energy (ONE) is advancing EV circularity by pairing cobalt- and nickel-free LFP batteries with U.S. manufacturing and grid-scale storage—so materials travel fewer miles, packs last longer, and end-of-life flows are simpler to manage. From vehicles to data centers, ONE helps OEMs, fleets, and recyclers reduce cost and risk while keeping critical minerals in the loop. 

At the heart of ONE’s offering are Aries™ and Aries II LFP packs for mobility, the Gemini™ long-range platform, and Aries™ Grid stationary systems—all fed by ONE Circle, the company’s Michigan gigafactory scaling cells, modules, and BMS. This integrated footprint supports domestic supply chains, higher traceability, and circular design from day one. 

LFP for Durability & Safety
Aries LFP delivers ~3,000 cycles and enables daily 100% charging without the nickel/cobalt supply risks—ideal for commercial EVs and lower-maintenance operations. 

Domestic Manufacturing
ONE Circle produces U.S.-made cells and packs, with capacity sized to serve hundreds of thousands of EVs annually—strengthening secure, local material flows. 

Range Efficiency by Design
Aries II narrows the gap to leading NCM packs to within ~6% on range and mass, while Gemini demonstrated 608 miles in a BMW iX—extending useful life and reducing pack swaps. 

Grid & Second-Life Pathways
Aries Grid brings LFP storage to factories, communities, and data centers—creating natural destinations for repurposed packs and accelerating eventual recycling with standardized formats. 

As automated recycling scales, ONE’s chemistry choices, U.S. production, and grid integration give the EV ecosystem a practical path to circularity—more safe miles per kilogram today, and better-organized reuse and recovery tomorrow.

Bridge Green Upcycle

Multi-Tech Upcycling & Digital Traceability for Cleaner, Circular EV Batteries

Bridge Green Upcycle is redefining end-of-life management with a multi-technology, multi-form-factor platform that turns retired and scrap lithium-ion batteries into high-grade black mass and battery-ready precursor materials—maximizing value with “nothing in the air and nothing on the ground.” The result is safer, lower-carbon recovery for recyclers, OEMs, and cathode producers across North America. 

At the heart of Bridge Green’s offering is an integrated flow: AI-enabled Battery Digital Technology Stack for rapid SOH prediction and EOL recommendations; selective pre-processing and purification for black-mass extraction; and conversion to high-purity precursors ready for reintegration into new batteries. A dedicated Infinity Lab & Prototype Facility on New York’s Huron Campus demonstrates these capabilities at pilot scale while de-risking commercial deployments. 

Black Mass → Precursor Conversion
Engineered pathways upgrade mixed feedstocks into consistent, high-purity intermediates—shortening routes to new cathode materials and stabilizing domestic supply. 

Digital Grading & Traceability
An AI battery stack predicts SOH and prescribes reuse vs. recycle, creating data-rich, audit-ready records that improve pricing, safety, and logistics. 

Second-Life Enablement
Dedicated workflows route healthy modules into stationary applications before materials recovery—extending value while reducing waste. 

Low-Carbon, Regulation-Ready
Process innovation targets superior yields with a minimized footprint, supported by live demonstrations at the Infinity Lab.

Ecosystem & Momentum
Backed by Launch NY and embedded in New York’s energy-storage cluster, Bridge Green is scaling with regional partners to accelerate circular materials flows. 

As EV volumes surge, Bridge Green Upcycle delivers a practical, data-driven route to circularity—recovering more value, cutting emissions and handling risks, and sending verified materials back into the next generation of batteries.