Repair & remanufacture
When a repair isn't enough, our experts are on hand to rebuild your EV or hybrid battery pack to its original condition so it can continue to perform at its best for longer.
Quality you can trust
We provide expert battery repair services that extend the first life of your EV batteries.We are committed to delivering work to the highest possible standards, aligned to those used in production.
Every stage of our work is carried out with precision and before any task is considered complete it under thorough inspection, testing and validation to confirm it meets our strict performance and regulatory criteria. This uncompromising approach ensures everything we deliver is robust, dependable and ready for operation.
Disassembly:
We safely open the battery pack to access individual components requiring repair
Repair:
Failure is often due to one or two components. Our repairs include:
- Module replacement
- Connector & cable repair
- Thermal management repair
- Battery balancing
Assembly & testing:
The battery is re-assembled and validation testing is completed to ensure every battery meets safety, functionality & agreed quality standards.
Why repair?
EV battery remanufacturing involves restoring a used battery to a like-new condition, by replacing or refurbishing key components. While the process is more extensive than repair, it’s far less resource-intensive than recycling and helps to maximise the life and value of the materials in every pack in its first life.
The benefits of remanufacturing include:
- Cost savings: Remanufacturing is often cheaper than producing a new battery
-
Resource efficiency: It reduces the demand for raw materials like lithium, cobalt, and nickel.
-
Reduced environmental impact: Remanufacturing helps extend the life of the battery, delaying the need for full recycling and reducing the overall environmental footprint.
What do repair and remanufacturing typically involve?
01
Diagnostics and testing
Functional safety checks are performed and technicians assess the EV battery's overall health and capacity, checking for issues like voltage imbalances, temperature control problems, and performance degradation.
02
Disassembly
The battery pack is disassembled using industrialised processes and equipment to ensure that no damage is introduced to re-useable components throughout the disassembly process.
03
Inspection and grading
All components are assessed to determine reuse or replacement requirements, based against an agreed specification and inspection criteria. All battery modules and cells are graded using EV Battery solutions advanced in house designed equipment to determine a true state of health value
04
Module and parts replacement
Battery packs are remanufactured using a mixture of new service and recovered re-certified components to a defined state of health using OEM production assembly processes and equipment.
05
Upgrading compononents
Over the lifecycle of a battery pack, OEM's introduce running changes to improve performance and reliability, where possible EV Battery solutions can upgrade older packs to the latest design iteration introducing those design changes to increase the lifespan of the battery pack.
06
Validation and re-certification
100% of battery packs that go through our industrialised remanufacturing process are validated and re-certified through our class leading End-of-Line testing capabilities. Battery packs are tested to OEM specifications and only once they are re-certified through out system can them be prepared for their onward journey.
Meet decarbonisation goals
Repair uses 90-95% less CO2 than recycling and replacement and reduces raw material demand.
Maximise battery value
Repair is cheaper and enables you to extract as much value from the batter in first and second life.
Protect vehicle value
Total cost of ownership is key in the EV buying process. Repairability drives residual value as consumers look for cost effective solutions.
10+
years of in-life battery solutions experience
50,000+
sq ft of engineering space to meet your battery servicing needs at scale
