The EU MARBEL Project, coordinated by the Eurecat Technology Center, has developed an innovative modular electric vehicle (EV) battery concept focused on eco-design and second-life reuse. The new prototype supports circular economy goals by streamlining battery assembly, disassembly, and repurposing, while enabling predictive diagnostics and ultra-fast charging.
The MARBEL battery prototype is engineered for ease of integration, repair, and recycling. Its modular structure allows individual components to be reused or replaced more efficiently, extending the pack’s usable lifespan. Each unit includes up to 60% post-consumer recycled aluminum, contributing to a reduction of up to 777 kg of CO₂ equivalent emissions per battery pack.
Designed for performance and sustainability, the system supports high-speed charging through a dedicated cooling system that ensures uniform heat dissipation from cells and busbars. Optimization algorithms refine the charging process, while a switchable junction box enables seamless operation across 400 V and 800 V systems, enhancing flexibility across EV platforms and battery configurations.
According to Eduard Piqueras, MARBEL Project Coordinator and European Program Manager at Eurecat, “The focus on circularity creates a pathway to more sustainable electric vehicle technology. At the same time, by optimising battery performance, we address the main hurdles that hinder electric vehicles’ acceptance and adoption, such as limited range and lengthy charging times, enabling longer trips.”
Design for Second Life and End-of-Life Recovery
A core objective of the MARBEL initiative has been to extend battery life through second-life applications—enabling reuse, refurbishment, and repurposing in non-automotive energy systems. This approach preserves material value while reducing waste.
“By integrating eco-design principles such as modularity, second-life applications, and materials with a high percentage of recycled content, MARBEL has extended battery usage while maintaining material value, effectively reducing waste and advancing both sustainability and economic viability,” explains Violeta Vargas, researcher in Eurecat’s Waste, Energy, and Environmental Impact Unit.
The battery system also incorporates advanced recovery strategies for high-purity graphite, lithium, nickel, manganese, and cobalt, in full compliance with the EU’s Sustainability Rules for Batteries and Waste Batteries regulation.
Smart System Architecture and Predictive Monitoring
The MARBEL prototype features a smart, modular power busbar design that enables tool-free assembly and simplifies integration while withstanding vibration in real-world driving environments. Its structural formats were refined to ensure mechanical robustness and efficiency.
Each cell is equipped with an intelligent Smart Cell Manager (iSCM) that communicates with the Battery Management System (BMS) via Bluetooth, replacing meters of wiring with just 80 centimeters in a 16-cell pack. This significantly reduces weight, cost, and assembly complexity while enhancing system performance.
Data from the BMS and iSCMs is processed by a digital twin powered by AI and machine learning algorithms. This web-based tool offers predictive insight into remaining battery life, charge state, and health status. It enables optimized second-life planning based on each component’s condition.
About the MARBEL Project:
The MARBEL Project is funded by the European Union’s Horizon 2020 program and involves a consortium of 16 partners across eight countries. The project has received funding from the European Union’s Horizon 2020 program. The MARBEL consortium includes 16 partners across eight countries: six universities and research centres (Eurecat, project coordinator; the Catalonia Institute for Energy Research (IREC); SINTEF; ICCS at the National Technical University of Athens; Technische Hochschule Ingolstadt; and Fraunhofer IWU), one automotive engineering company (Applus IDIADA), two SMEs (Powertech Systems and OTC Engineering), and five component manufacturers (FICOSA, AVL Thermal HVAC, AVL Italia, ASAS, Agrati, and SK Tes).
Stellantis (CRF) represents the OEM contribution to the project. Together, these partners have developed a compact, modular, and lightweight EV battery platform designed to deliver high performance, fast charging, extended service life, and post-automotive reuse—supporting the scalable growth of electric mobility across Europe.
For more information, please click here.
Source/Photo Copyright: MARBEL Project
(Editor’s Note: All trademarks mentioned in this article, including company names, product names, and logos, are the property of their respective owners. Use of these trademarks is for informational purposes only and does not imply any endorsement.)
