Researchers at Graz University of Technology (TU Graz) and the University of Graz have developed design guidelines intended to improve the safety, repairability, and recyclability of electric vehicle battery packs.
The work, conducted through the E-Track research project, examined conventional bonded battery housings alongside alternative designs intended to make packs easier to disassemble and repair. One concept uses replaceable housing covers and thermal pads, while another uses a sealed, bolted housing with electrically insulating oil for cooling.
Three battery pack designs evaluated in the study: (a) sealed housing, (b) exchangeable-lid design, and (c) liquid-filled design. (Image: Oka et al., Sustainable Production and Consumption, via ScienceDirect)
The researchers found that repair-friendly designs can provide environmental benefits when as little as 8% of the battery cells are reused. Battery cells account for roughly 75% of the pack mass examined in the study, making their recovery after damage an important factor in cost and life-cycle impact.
As part of the broader E-Track project, the team also developed diagnostic methods using electrochemical impedance spectroscopy combined with multiphysics models to identify internal cell damage, including micro-shorts that could contribute to delayed battery failures.
“Without uniform design standards, emergency services often face major challenges in an emergency because the structure and behaviour of battery systems are difficult to assess,” said Markus Fasching, project manager at TU Graz’s Vehicle Safety Institute. “At the same time, we lose valuable resources if batteries cannot be repaired or fully recycled.”
The guidelines were developed primarily for electric two-wheelers, but the researchers said the methods and simulation approaches can be applied to larger EVs, including passenger vehicles and trucks.
A peer-reviewed study from the project examining how EV battery pack design for disassembly affects environmental and circularity impacts was published in Sustainable Production and Consumption. The E-Track project was led by TU Graz’s Vehicle Safety Institute in collaboration with the University of Graz’s Institute of Environmental Systems Science and industry partners.
Resource
Oka, P.T.S., Schinagl, M., Krassnitzer, P., Fasching, M., Stern, T., and Mair-Bauernfeind, C. “Design matters: The influence of EV battery pack design for disassembly on environmental and circularity impact.” Sustainable Production and Consumption, Vol. 65, 2026, pp. 179–192. DOI: 10.1016/j.spc.2026.04.003
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