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New battery block architecture repurposes Tesla cells

By Michelle Froese | April 1, 2025

re/cell, a provider of remanufactured battery technologies, has unveiled its latest innovation: lithium-ion “blocks,” created from previously used Tesla battery cells. This move taps into the vast reservoir of existing cells to meet growing secondary market demands for electric vehicles (EVs), drones, and energy storage solutions.

In conjunction with this launch, re/cell introduces a reference battery architecture specifically designed for heavy-payload drones and UAVs. This architecture is poised to benefit the logistics and agriculture industries.

The smart battery features include an LED fuel gauge, charge warning, integrated cooling, and real-time monitoring through CAN/SMBus communication. The technical specifications for these blocks are as follows:

  • 17Ah / 44.4V / 755 Wh: Dimensions of 220 H x 90 D x 135mm W, with a peak output of 100A and continuous output at 54A for 15 minutes at 80% DoD.
  • 23Ah / 44.4V / 1020 Wh: Dimensions of 220 H x 90 D x 175mm W, with a peak output of 140A and continuous output at 72A for 15 minutes at 80% DoD.
  • 46Ah / 44.4V / 2040 Wh: Cell weight of 8,840g, peak output of 280 A, and continuous output at 144 A for 15 minutes at 80% DoD.

re/cell has been at the forefront of EV battery pack remanufacturing for over ten years, providing peace of mind to both EV and UAV operators. The company also manufactures replacement packs for all Tesla models, including the Model S, Model 3, and the Tesla Roadster.

“We have a wealth of lithium-ion cells in existing Tesla packs that can be effectively repurposed,” explained Chad Maglaque, founder and president of re/cell. “Our new ‘block’ architecture, supported by a patent-pending recovery process, enables the production of high energy density battery blocks with customizable capacities ranging from 12 to 48 amp hours or more.”

 

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Filed Under: Batteries, Technology News
Tagged With: re/cell
 

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