Tightness Testing for High-Recyclability EV Assembly Designs (TIGHT-THREAD)

Purpose and goal

The aim is to enable circular battery packs for electric vehicles by replacing adhesively bonded joints with mechanical joints. The goal is to establish a framework for standardized evaluation of fastener tightness. Specific objectives include mapping test methods, evaluating the sealing of multiple fasteners, designing a conceptual test rig, and creating a roadmap for a future demonstration project.

Expected effects and result

The project is expected to drive the transition to repairable and sustainable battery systems for electric vehicles. Eliminating adhesives enables and improves non-destructive disassembly, facilitating repairs and extending the battery life. This reduces the carbon footprint and increases residual value. It also prevents adhesives from potentially contaminating metal recycling streams, providing purer secondary raw materials and supporting the EU’s circular economy goals.

Planned approach and implementation

The feasibility study is led by RISE and will last for eight months with partners such as Volvo Cars, Arnold, Atlas Copco and Nedschroef. The approach is based on three work packages (WP). WP1 maps test standards and defines requirements based on the vehicle environment. WP2 conducts experimental leak testing and material analysis of innovative fasteners. Finally, WP3 handles project management and workshops to prepare a full-scale demonstration project.