Altilium Produced the UK’s First EV Battery Cells with Recycled Materials

Altilium, a clean technology company based in the UK, has achieved a groundbreaking milestone in the push toward more sustainable electric vehicles (EVs). The company announced that it has successfully produced the UK’s first EV battery cells using recycled cathode active materials (CAM) at the UK Battery Industrialisation Centre (UKBIC) in Coventry, marking a significant step towards a circular economy for EV batteries.

This milestone is particularly noteworthy as it represents the first time that recycled materials have been used in the production of battery cells in an industrial setting in the UK. It also addresses the country’s increasing demand for environmentally responsible solutions. Altilium stated that the newly produced battery cells will undergo rigorous validation tests with a leading automotive Original Equipment Manufacturer (OEM), supporting sustainability targets and ensuring compliance with evolving regulatory standards.

A Breakthrough in Sustainable Battery Manufacturing

According to Altilium, the pouch cells were produced at the UKBIC’s cutting-edge facility in Coventry, utilizing Altilium’s recycled EcoCathode™ NMC 811-2036 CAM, which is manufactured at their recycling plants in Devon. By reclaiming essential metals from end-of-life EV batteries and Gigafactory waste, Altilium is not only reducing the UK’s dependence on imported raw materials but also lowering the carbon footprint of battery production, making electric vehicles even more environmentally friendly.

Dr. Christian Marston, Altilium’s co-founder and COO, expressed his enthusiasm about this historic achievement, stating, “This milestone marks the first time full battery circularity has been achieved in the UK, from recovering critical minerals... Having access to a manufacturing facility like this allows us to scale up and develop this innovative work, which is helping to position the UK at the forefront of sustainability and decarbonisation.”

Compliance with Upcoming EU Regulations

This breakthrough also carries significant regulatory importance. Starting in 2031, new EV batteries sold in the European Union will be required to contain a minimum percentage of recycled lithium, nickel, and cobalt, with further increases mandated in 2036 under the EU’s Battery Regulations. Altilium’s cells are the first to be manufactured in the UK to comply with these future regulations, setting a benchmark for other manufacturers in the region.

Ameir Mahgoub, Head of Product Engineering at UKBIC, commented, “We’re delighted to have been part of the team creating the UK’s first battery cells made using CAM containing recycled material. This pioneering project could be just the start of a journey that sees the UK becoming less reliant on imported materials and create a new market in recycled EV batteries. We look forward to collaborating with Altilium on this exciting project as they take it forward.”

The Recycling Process: A Game-Changer for Sustainability

According to Altilium, the recycling process begins by dismantling and shredding old EV batteries to produce black mass—a fine powder rich in critical metals. Using its proprietary EcoCathode™ process, Altilium recovers more than 95% of the essential metals, including lithium. These metals are then upcycled to create high-nickel NMC 811 cathode materials, which are reused in the production of new, high-performance batteries.

This innovative process not only reduces the need for new mining but also addresses the environmental concerns associated with the disposal of old batteries. As the demand for EVs continues to rise, the need for sustainable, closed-loop solutions to manage battery waste becomes even more critical.

Scaling Up for Future Demands

Altilium revealed its plans to develop its ACT4 recycling plant in Teesside, which is expected to produce 30,000 tonnes of CAM annually, enough to supply nearly 20% of the UK’s anticipated EV battery demand by 2030.

The expansion of Altilium’s recycling operations will not only reduce the country’s reliance on imported raw materials but also help meet the growing demand for battery raw materials in emerging green industries. The project is a critical part of the UK’s broader strategy to achieve net-zero emissions by 2050.

As Altilium continues to advance its innovative recycling technologies, the company is well-positioned to play a significant role in reshaping the UK and European automotive supply chains. By providing high-volume, low-carbon domestic sources of battery materials, Altilium is helping pave the way for a more sustainable, circular economy in the EV sector.