UK battery technology company Integrals Power is to manufacture and supply hundreds of kilograms of its patented manganese-rich lithium manganese iron phosphate (LMFP) cathode active material to a new UK government-funded project to develop advanced battery technology for the defence and automotive sectors. LMFP can be produced from raw materials sourced from Europe and North America, and does not use critical minerals.

The 30-month, £2m (US$2.69m) program, led by specialist battery supplier Denchi, will produce hundreds of demonstrator cells in pouch and cylindrical form factors – the latter in both 21700 and 4695 sizes. These will be manufactured on the UK Battery Industrialisation Centre‘s (UKBIC) new Flexible Pilot Line in Coventry, then assembled into battery packs at Denchi’s facility in Thurso in Scotland.

Funding has been secured through the Battery Innovation Programme, delivered by Innovate UK and supported by the Department for Business, Innovation, Science and Trade.

Integrals Power founder and CEO Behnam Hormozi said, “Our involvement in this program reflects the growing recognition that LMFP will transform battery performance, cost and supply chain resilience. By eliminating reliance on critical minerals such as cobalt and nickel while delivering higher energy density than LFP, LMFP is well suited to the evolving requirements of both defence and automotive applications. We are proud to contribute our materials expertise to a project that is helping to advance secure, sustainable battery technologies in the UK and beyond.”

The first validation trials will be carried using Denchi’s current BB-2590 design, which was developed specifically for military use, including radios, sensor systems, unmanned aerial and ground platforms and back-up power supplies for aircraft and marine systems. These ruggedized, waterproof packs, which weigh around 1.35kg, will have the existing nickel manganese cobalt (NMC) cells replaced by the new LMFP cells.

“With more than 20 years’ experience supplying the military with British designed and built battery systems, we have a very clear understanding of what the defence sector needs as electrification becomes a core element of future strategy,” said Andrew Cowie, CEO, Denchi Group. “Sovereign capability is absolutely paramount, and by working in partnership on this program with Integrals Power, UKBIC and the UK government, we are playing our part in delivering exactly that. We look forward to building the first LMFP battery packs and getting them out into the field for validation trials.”

China currently dominates global LFP battery production, but tighter export controls on LFP cells, materials and manufacturing technology are increasing concerns over supply chain resilience. As LFP batteries continue to gain market share due to their lower cost, safety and durability, OEMs in Europe and North America are seeking to diversify supply and reduce dependence on Chinese manufacturing.

“Collaboration across the UK battery ecosystem is essential to translating innovation into long-term, strategic capability. Our new Flexible Pilot Line has a key role to play in this because it enables customers to accelerate the cost-effective scale-up of their technologies,” said Sean Gilgunn, UKBIC managing director. “Supporting the development of LMFP cells within an integrated UK supply chain is an important step toward strengthening long-term competitiveness in a broad range of sectors, including defence and automotive.”

Integrals Power’s LMFP material has a high manganese content of 80%, which enables up to 20% greater energy density than conventional LFP while retaining its key advantages. This combination of attributes, together with freedom from expensive cobalt and nickel and makes it a compelling alternative.

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BMW’s Plant Woodruff in South Carolina will begin series production of the Gen6 high-voltage batteries for the fully electric BMW iX5 in December, and the auto maker has revealed further details of the technology that will underpin the production process.

The facility uses AI-supported production processes, digital twins and virtual reality applications, with the auto maker stating that “the new plant is setting industry standards for the assembly of high-voltage batteries”. The BMW X5 premiered on June 30 at the auto maker’s South Carolina Plant Spartanburg facility, which it refers to as “the Home of X”.

“Plant Woodruff plays a key role in the ramp-up of electromobility in the US,” said Raymond Wittman, member of the board of management of BMW responsible for Production. “With our Gen6 high-voltage battery, we’re not only taking a major technological leap – we are also setting new standards in production. In Woodruff, we are combining cutting-edge processes, artificial intelligence and the expertise of our employees to create a production facility designed for the highest quality.”

“With Plant Woodruff, we are further expanding our footprint in South Carolina and strengthening the close integration of battery and vehicle production,” said Robert Engelhorn, president and CEO of BMW Manufacturing. “This creates the ideal foundation for the next generation of fully electric BMW X models assembled at Plant Spartanburg.”

Intelligent production for maximum quality 

The cylindrical cells are integrated directly into the high-voltage battery, based on the cell-to-pack principle. All production steps are continuously monitored inline and comprehensively documented in real time. In-house developed AI assistants and agents analyze this data and, together with more than 300 employees and 250 robots at Plant Woodruff, ensure the zero-defect battery production. At the same time, the extensive use of artificial intelligence enhances overall equipment effectiveness (OEE) in production. Well before commissioning, digital twins of production and virtual reality applications support planning and employee training.

Training in a virtual factory 

All production staff at Plant Woodruff complete a VR training program developed on-site. Within a virtual factory, they can practice real manufacturing operations under realistic conditions. This virtual environment replicates the plant’s production lines in meticulous detail, requiring only a set of VR goggles and a PC.

Three years from start of construction to series production 

Following the official groundbreaking in June 2023, construction of the plant began in September 2023. In September 2024, while construction was still under way, installation of the manufacturing equipment commenced. Preparations for production started in summer 2025, and the first test and pre-series batteries have been rolling off the assembly line since then. The series launch is scheduled for December 2026.

“Plant Woodruff demonstrates how quickly we can scale a new battery concept to industrial production,” said Rich Everly, vice president of production at BMW Plant Woodruff. “The key factor is the synergy between a skilled and dedicated team and the continuous exchange of experience within the production network.”

Gen6 battery cells with reduced carbon footprint 

The Gen6 battery cells used in the BMW iX5’s high-voltage battery include a high proportion of secondary materials in the cobalt, lithium and nickel content. Renewable energy is also used in the production of anode and cathode materials, as well as in cell manufacturing. Compared with the Gen5 cell used in the BMW iX, CO2 e emissions have been reduced by around 28% per watt-hour. Plant Woodruff does not use any fossil fuels during normal operations, while the site’s industrial trucks are powered by hydrogen.

Assembling the Gen6 high-voltage batteries 

At BMW Group Plant Woodruff, battery cells undergo a series of automated assembly and inspection processes, including voltage checks, cell clustering, laser cleaning and precision welding, with inline monitoring of every weld seam. The batteries are then foam-encapsulated, sealed and fitted with the Energy Master control unit before completing a 100% end-of-line inspection. Finished battery packs are transported to the nearby BMW Group Plant Spartanburg for vehicle assembly.

800V, with high energy content 

The first battery-electric BMW iX5 is based on sixth-generation BMW eDrive technology, featuring cylindrical cells and 800V technology. With an available energy content of 144kWh, the BMW iX5 60 xDrive boasts the largest high-voltage battery of any fully-electric BMW model to date.

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UK battery technology company Integrals Power has been selected to supply its manganese-rich lithium manganese iron phosphate (LMFP) cathode active material to Olimpus, a €9m (US$10.3m) Horizon Europe project to develop and industrialize LMFP battery cells using a European supply chain. Mass production of LMFP cells in Europe is targeted by 2032, with electric vehicles and maritime applications as the primary end uses.

Coordinated by Norwegian research organisation SINTEF, Olimpus brings together 16 partners from across the battery value chain, including Volvo Trucks, Magna Steyr, cell manufacturer Verkor, synthetic graphite anode supplier Vianode and Corvus Energy. As well as supplying more than 150kg of LMFP cathode active material, Integrals Power will also be responsible for scaling up and industrializing the manufacturing process and supporting cell prototyping and performance validation.

Running until 2030, the project will produce over 130 automotive-grade cells on SINTEF’s pilot lines and at Verkor’s gigafactory facilities, in both pouch and prismatic form factors and capacities ranging from 10h to 80Ah, with a target energy density of up to 220Wh/kg.

Sustainability is a key focus. Water will replace the toxic and highly flammable solvent NMP, a semi-dry electrode coating process will reduce energy use in the drying stage compared to conventional wet slurries, and synthetic graphite for the anode will be used to lower the overall carbon footprint. Compared to nickel cobalt manganese chemistry, NMC81, Olimpus projects a reduction in lifecycle CO₂-equivalent emissions of approximately 1.8 million metric tons by 2050.

Integrals Power founder and CEO Behnam Hormozi said, “Our participation in Olimpus is the clearest demonstration yet that Integrals Power’s patented LMFP technology is a key enabler for establishing sovereign battery capability in the UK and Europe. Third-party testing has already proven its high energy density, cycle life and cold weather performance, and this project represents the next milestone in its development as we optimize the materials and processes for scale-up.

“A successful transition from fossil fuels to clean energy sources can only be achieved with a robust, transparent, sustainable and cost-effective battery supply chain, and that requires alternatives to cell chemistries and manufacturing reliant on critical minerals and Chinese technology. The Olimpus project is laying the foundations for this, and we are extremely proud to be a part of it.”

Integrals Power’s LMFP material has a high manganese content of 80%, which enables up to 20% greater energy density than conventional LFP while retaining its key advantages of cost, safety and long cycle life. This combination of attributes, together with freedom from expensive nickel and cobalt, makes it a compelling alternative to NMC, which is still the dominant cell chemistry for electric vehicles made by European and North American vehicle manufacturers.

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Shell has unveiled the Triple 10 Challenge concept car, a proof-of-concept vehicle designed to “inspire a new design philosophy for the next generation of battery electric vehicles”.

The compact, mass-market EV demonstrates next-generation electric vehicle capability and offers the industry an alternative to the current reliance on ever-larger batteries by re-imagining the fundamentals of thermal management.

The vehicle meets three ambitious goals that Shell believes can help drive the future of mass-market electric mobility: a sub 10-minute charge time, 10km/kWh economy and a lifecycle 10-metric ton CO2e footprint. These are achieved using Shell’s advanced thermal fluids to achieve optimized thermal management.

The Challenge demonstrates the potential of a simplified, single-circuit cooling architecture to manage the thermal load of the car’s powertrain under extreme fast-charging scenarios in real-world conditions, Shell said.

Cara Tredget, VP mobility and lubricants technology for Shell, said, “With the Triple 10 Challenge concept car, we have unlocked the potential for faster charging, lighter systems and improved lifecycle efficiency by using our advanced thermal fluids. Together with our co-engineering partners, we are proud to develop alternative options for sustainable EV development, leveraging technologies that are available today and are scalable to support customers into the future.”

The concept car has been designed to achieve 10km/kWh in driving economy with a smaller, more efficient battery system, with a more than 30% improvement in overall energy efficiency compared with many current-generation EVs.

The vehicle can charge its battery from 10% to 80% in 9 minutes and 54 seconds, while maintaining thermal stability and battery longevity, according to the company. Unlike many ultra-fast-charging EVs that require chargers rated above 300kW, the vehicle achieves this performance using a standard 175kW charger available on existing charging networks.

At this charging rate, the vehicle adds up to 24km of driving range per minute, compared with an average of 13km per minute for typical battery-electric vehicles using the same charger – nearly 90% more range added per minute of charging.

The concept car is estimated to have a lifecycle carbon footprint of approximately 10 metric tons CO2e. Enabled by its lightweight design, optimized battery capacity, low-carbon and recyclable materials, together with 100% renewable electricity for vehicle charging, this is estimated to represent around a 50% reduction in lifecycle emissions compared to typical battery electric vehicles in the European market.

Immersive thermal management: Shell Recharge

Unlike traditional cooling systems that use water-glycol, Shell’s Recharge dielectric fluid enables direct immersion cooling of the battery and indirect cooling of the powertrain components, including the motor and power electronics. By redefining heat management across the battery and powertrain, the team has unlocked the potential for faster charging, lighter systems and improved lifecycle efficiency.

By incorporating a more compact and efficient battery pack design with fewer modules and using Shell’s advanced thermal fluid, enabling a simplified housing architecture, these improvements contribute to about a 25% reduction in overall battery pack cost compared to a conventional EV.

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BMW has announced that the X5 has entered the finishing straight of its development program, including final calibration drives around its production base at Plant Spartanburg in the USA. The auto maker has also confirmed that the X5’s carbon footprint has been cut by around 40% compared with industry averages, driven by a sweeping overhaul of its supply chain, production processes and battery technology. The vehicle’s sustainability credentials are supported further by the iX5’s sixth-generation eDrive technology, Gen6, which features an 800V battery architecture that delivers 30% faster charging and 30% greater range, the auto maker.

Gen6 battery cells with reduced carbon footprint

The Gen6 battery cells used in the iX5’s high-voltage battery – which were unveiled in 2025 and designed for Neu Klasse vehicles before being rolled out across the auto maker’s electric vehicle portfolio – include a high proportion of secondary materials in the cobalt, lithium and nickel content. Renewable energy has also been also used in the production of anode and cathode materials, as well as in cell manufacturing. Compared with the Gen5 cell used in the BMW iX, CO₂e emissions have been reduced by around 28% per watt-hour.

Efficiency during use phase 

The BMW iX5 incorporates the auto maker’s EfficientDynamics technology package, which improves vehicle efficiency across key systems, including aerodynamics, lightweight construction, low rolling-resistance wheels and tires, and overall energy management.

The vehicle also features BMW’s “Heart of Joy” control unit and the in-house-developed BMW Dynamic Performance Control driving stack, technologies shared with the BMW iX3 and BMW i3. These systems are designed to enhance drivability, providing smooth acceleration and braking while improving energy efficiency. During deceleration, the vehicle can recover more energy through regenerative braking across a wider range of driving conditions, including down to a complete stop.

Supply chain decarbonization as key lever

Targeted decarbonization throughout the supply chain is a key lever for reducing CO2e emissions. The BMW Group is focusing in particular on renewable energy and secondary materials, as well as product and process innovations. During the product development process, CO2e emissions of the BMW X5 were reduced by around 40%.

A further advance is the increased use of CO2e-reduced flat steel. Around 50% of the flat steel used in the BMW X5 is electric arc furnace steel (EAF steel) with a high proportion of secondary material, produced using renewable energy. The high share of CO₂e-reduced flat steel is the result of close, long-standing collaboration with local suppliers in North America.

Systematic use of secondary materials 

The X5 achieves a high proportion of secondary raw materials, even in heavy-duty components. These include aluminum suspension components such as wheel rims, swivel bearings, wheel supports, rear axle supports and brake callipers, which are manufactured using renewable energy for both electrolysis and production.

The aluminum used for the doors of the BMW X5 contains 35% recycled and closed-loop material from BMW Spartanburg’s press shop. The base material used for the yarn of the headliner fabric is made from 100% recycled PET. In the battery-electric BMW iX5 60 xDrive, around one third of the total vehicle is made up of secondary raw materials, equivalent to a weight of 940kg.

Carbon payback period

Comprehensive decarbonization measures across the supply chain, production and use phase result in an early breakeven point. Depending on the drivetrain variant, annual mileage and source of the electricity used for charging, the BMW iX5 60 xDrive achieves a CO₂e advantage over a comparable model with an internal combustion engine after approximately one to two years of use.

The BMW Group will publish the Product Carbon Footprint for the BMW X5, validated by the German Technical Inspection Association (TÜV), to accompany the series launch.

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The all-electric Mercedes-AMG 4‑Door Coupe is based on the high-performance AMG.EA architecture and features a new drive concept comprising axial flux motors developed by the British electric-motor specialist Yasa and a high-performance battery that shifts “the benchmark in the high-performance segment”, the auto maker said.

Mercedes‑AMG demonstrated the capability of this drivetrain technology last year with the record drive of the Concept AMG GT XX in Nardò, Italy, where the technology demonstrator sprinted over 40,000km in seven days and 13 hours, breaking a total of 25 long-distance records in the process. (Read more on the concept in the April 2026 issue of APTI).

Mercedes-AMG is offering two powertrains: the Mercedes‑AMG GT 63 4-Door Coupe and the Mercedes‑AMG GT 55 4-Door Coupe.

“From my time at AMG, I know how high the bar is set in Affalterbach. With this first model on the new AMG.EA architecture, we don’t just meet it, we move it,” said Ola Källenius, chairman of the board of management, Mercedes‑Benz Group.

Three key aspects contribute significantly the performance capability: new battery cells, an innovative direct cooling system for each individual cell and a comparatively high voltage.

Electric power

The sports car uses three electric motors, two on the rear axle and one at the front, that deliver a system output of up to 860kW (1,169hp). These are complemented by a high-performance battery concept. Together, these achieve a 0 to 100 km/h time of just 2.1 seconds, with the vehicle requiring only 6.4 seconds to accelerate from 0 to 200 km/h. It’s top speed is 300 km/h (with optional Driver’s Package).

Thanks to a charging capacity of 600kW, over 460km of range can be recharged in just 10 minutes. A typical charging cycle from 10% to 80 % state of charge (SoC) takes 11 minutes.

In an axial flux motor, the electromagnetic flux runs parallel to the motor’s axis of rotation, unlike conventional electric motors where it runs perpendicular. The design uses a stator positioned between two rotor discs in an H-configuration to improve magnetic efficiency.

The electric motors are integrated into High-Performance Electric Drive Units (HP.EDUs) on each axle. At the rear, two axial flux motors are combined with a compact single-stage planetary gearbox within a shared housing. The system includes oil cooling, an integrated pump control unit and water-cooled silicon-carbide (SiC) inverters, designed to support high-voltage and high-performance operation. The axial flux motors can exceed 13,000rpm.

The front HP.EDU includes an axial flux motor, transmission, silicon-carbide (SiC) inverter and pump control unit. The motor can exceed 15,000rpm and operates as a front-axle booster motor, engaging when additional power or traction is needed.

“This vehicle underscores the broad performance spectrum of our comprehensive development strategy and the consistent transfer of the Concept AMG GT XX technology program into series production,” said Jörg Burzer, member of the board of management and chief technology officer, development and procurement, at Mercedes-Benz Group.

Newl battery cell for high performance 

At the heart of this innovation is a cylindrical, tall and slim battery cell. This format provides advantages for cooling. The small diameter minimizes the distance from the cell core to the surface, enabling rapid and efficient dissipation of heat generated under load, ensuring each round cell is maintained within its optimal temperature range. Laser-welded aluminium cell housing is also a new development, offering outstanding electrical and thermal conductivity.

A full-tab cell design reduces internal resistance by connecting the cell windings across the full surface of the poles, supporting higher charging and discharging performance while maintaining reliability under demanding conditions.

The cell chemistry is based on NCMA (nickel/cobalt/manganese/aluminum) in the cathode and a silicon-containing anode.

Overall, the combination of the tall and slim format, aluminum housing, full-tab technology and NCMA chemistry provides the foundation for maximum performance.

Intelligent direct cooling for the battery cells

The new battery concept uses directly cooled cylindrical cells with a special cell chemistry that ensures uniform temperature distribution and high-performance stability under continuous load. In total, 2,660 cells are used in the Mercedes‑AMG GT 4‑Door Coupé. The individual cylindrical cells are grouped into 18 laser-welded plastic modules.

The high-voltage battery is integrated centrally into the structure of the e-skateboard. Its protective housing (safety box) encloses the cell modules, all switching components and the battery management system (BMS), also an exclusive AMG in-house development.

Under the transmission tunnel lies a highly advanced cooling system whose core is an innovative cooling module. This module serves as the central interface to the vehicle’s cooling system and integrates key components such as the coolant pump module (KMP), the oil-water heat exchanger (ÖWWT) and the necessary connectors for direct oil cooling.

The temperature of the BMS is actively regulated via a special cooling plate, enabling higher currents. For the first time, virtual sensors have also been used: the BMS determines temperatures – such as within a cell – not via physical components but through mathematical models based on the current charging power.

“The first all-electric AMG GT 4‑Door Coupé takes the AMG DNA to a whole new level,” said Bastian Baudy, chief design officer, Mercedes-Benz Group. “A vehicle that embodies high-tech and innovation, brings performance to life and will set new standards with its radical design approach.”

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A UK consortium has secured funding through the Battery Innovation Programme to develop ReCAM, a lithium-ion battery recycling project aimed at converting battery waste into cathode active materials for reuse in new batteries.

The project brings together the UK Battery Industrialisation Centre, Watercycle Technologies, Recyclus Group and Polaron to tackle the pressing challenge of a growing volume of end-of-life lithium-ion batteries and leveraging the black mass produced in the disposal and recycling process.

As electric vehicle adoption accelerates, the UK is projected to generate up to 94,000 metric tons of black mass annually by 2040, which contains highly valuable lithium, nickel, cobalt and manganese. However, the UK has no viable processing route to deal with black mass, leaving this material to often be exported overseas for processing, which results in lost economic value, increased emissions and reliance on international supply chains.

The ReCAM project introduces a patented, short-loop refining process that converts black mass directly into high-value cathode active material (CAM) for reuse in new batteries. Unlike current technologies, which break materials down into individual metals through a multi-stage chemical process, ReCAM uses a new next-generation approach that converts mass in a single streamlined step.

The process also recovers lithium efficiently and operates as a zero-waste system. Designed as a modular, on-site solution for recyclers, capable of processing 250 kg of material per hour, ReCAM enables more flexible and economically viable battery recycling in the UK.

Dr Ahmed Abdelkarim, co-founder at Watercycle Technologies, said, “By establishing a viable UK-based route for refining battery waste into reusable materials we can unlock significant economic value, reduce emissions associated with exports and enhance the resilience of the UK battery ecosystem.”

Robin Brundle, executive chairman at Recyclus Group, added, “We are delighted with this award and to be working with such gifted partners. This is a British-centric program built around UK resilience and that is something we at Recyclus are extremely proud of.”

Polaron will use its AI-based materials platform to help characterize and optimize the recycled cathode materials, linking process conditions to microstructure and performance. Polaron’s AI-driven cell design technology will dramatically accelerate the transition from materials to electrodes, and electrodes to cells.

Dr Isaac Squires, CEO and co-founder of Polaron, commented, “For recycled battery materials to be used again at scale, they need to prove they can be performant. Our role in ReCAM is to help the consortium understand how process conditions shape cathode microstructure and performance, so promising recycled materials can move closer to battery-grade use as quickly as possible.”

The initiative is funded under the UK’s wider £452m (US$616m) Battery Innovation Programme, which is being delivered by Innovate UK, part of UK Research and Innovation (UKRI) on behalf of the Department for Business and Trade.

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Rock Tech Lithium has partnered with Canada’s BMI Group to develop its lithium converter facility in Red Rock, Ontario. The collaboration is expected to take the form of a general partner/limited partner structure, with Rock Tech controlling the general partner and BMI acting as lead limited partner and anchor investor. Rock Tech will retain full control over project development, engineering, operations and key technical and strategic decisions.

Rock Tech is developing an integrated lithium platform in Canada, connecting upstream supply from the Georgia Lake project with downstream production at the Red Rock Converter. The project aims to create a domestic supply chain from mine to battery-grade lithium salts that aligns with IRA and CUSMA requirements, enhancing Canada’s critical minerals processing capabilities and supporting North American and European supply chains.

As part of the partnership, BMI Group plans to invest C$$200m (US$144m), with Rock Tech and additional partners contributing further equity over time. The project aims to establish processing capacity in Canada, enhancing value creation, supply security and planning certainty for North American industrial off-takers.

“BMI Group’s significant investment is a strong market signal. An experienced Canadian partner committing at this level demonstrates that our project is not only technically and economically compelling – it also enjoys the confidence of professional investors,” said Mirco Wojnarowicz, CEO Rock Tech. “This partnership structure reflects our philosophy: we bring the technology, the operational expertise and the proven converter concept. Our partners invest the capital with expected high returns. Together, we deliver.”

To advance near-term development, including a feasibility study, the partners plan a non-dilutionary funding program of up to C$30m (US$22m) matched by government contributions. The funds will support engineering, environmental and permitting work, and early site development ahead of a final investment decision by the end of 2026.

The Red Rock Converter leverages Rock Tech’s project in Guben, Germany, which is fully engineered and permitted, and designated a strategic project under the EU Critical Raw Materials Act. The Canadian facility will be built on BMI’s 337-acre industrial site, located 100km east of Thunder Bay and 60km south of Rock Tech’s Georgia Lake lithium deposit.

“As long-horizon developers, BMI Group sees its partnership with Rock Tech as one that will position Northwestern Ontario as a key hub in sovereign defence and battery materials supply chains,” said says Paul Veldman, CEO BMI Group.

“Our Red Rock platform provides industrial-ready infrastructure that compresses timelines from site selection to production. This investment reflects our confidence in Rock Tech’s technology, market strategy, leadership and long-term vision. Through our Canadian and European investor base, we are aligned on the need for secure, allied critical minerals processing capacity and the multi-sector coordination to get it done.”

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Electric vehicles (EVs), positioned as a sustainable alternative to internal combustion engine (ICE) vehicles, continue to face challenges related to material sustainability. Polestar has expanded its battery circularity efforts, announcing that batteries used in the Polestar 2 and Polestar 3 now contain at least 50% recycled cobalt. The milestone is part of a broader strategy to reduce reliance on virgin materials, improve supply chain transparency and extend the lifecycle of key resources.

During the vehicle use phase, the company focuses on extending battery life and preserving value for as long as possible. Polestar has partnered with Volvo Cars battery centers to refurbish high-voltage batteries, enabling Polestar 2 and Polestar 3 vehicles requiring replacements to receive refurbished units with equivalent state of health. This approach supports a circular flow of batteries, helping to maintain performance standards while reducing environmental impact and improving value retention.

Polestar is also establishing recycling partnerships across all its markets to meet producer responsibility requirements while extending battery lifecycles and maximizing material recovery.

Fredrika Klarén, head of sustainability at Polestar, said, “To drive a Polestar is an intentional choice by customers who care about tomorrow. Electrification, powered by renewable energy and enabled by circular battery materials, points to a new kind of system: one where resources stay in use and abundance replaces depletion.”

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The adoption of electric vehicles – BEVs, PHEVs and HEVs – is expected to increase in the mid to long term as the auto industry pursues carbon neutrality. Market demand for improved power efficiency is continuing to grow as a result, with motor generators, which play a critical role in extending driving range and improving the performance of electrified vehicles, increasingly required to operate at higher efficiency.

To meet these market needs, reducing power loss in motor generators is essential. Among various approaches, iron-based amorphous alloys – which can significantly reduce iron loss occurring in motor cores – are considered a promising material to realize high-efficiency motors.

In support of this, Denso has invested in Next Core Technologies (NCT) to co-develop advanced motor cores using amorphous alloy technology. The collaboration will combine NCT’s materials and processing expertise with Denso’s motor generator development capabilities, with the goal of enabling mass production of highly efficient motor cores for next-generation applications.

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