Advanced Light-weight BATteRy systems Optimized for fast charging, Safety, and Second-life applications.

Project Information

ALBATROSS

Grant agreement ID: 963580

DOI

10.3030/963580

Project closed

EC signature date 12 November 2020

Start date 1 January 2021

End date 30 June 2025

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 11 818 442,50

EU contribution

€ 9 991 817,89

Coordinated by

YESILOVA HOLDING AS
Türkiye

Periodic Reporting for period 3 - ALBATROSS (Advanced Light-weight BATteRy systems Optimized for fast charging, Safety, and Second-life applications.)

Reporting period: 2024-01-01 to 2025-06-30

Summary of the context and overall objectives of the project

The project created a full battery system concept by advancing every layer of design and operation. At the module level, lightweight housings and high-energy cells were combined so that the carrier tray itself contributed structurally, reducing redundant parts. Robust aluminium–copper busbars were laser-welded to ensure electrical performance and durability.
Thermal management relied on partial immersion cooling, complemented by ultra-thin printed heaters and sensors embedded directly into the modules. These sensors provided real-time data on temperature and strain, enabling precise control and cell balancing during charging and discharging.
A new Battery Management System (BMS) was introduced with advanced algorithms capable of early failure detection, predictive safety management, and flexible reuse across different pack configurations. The BMS not only managed voltage, current, and temperature with high precision but also enabled remote diagnostics and data-driven optimisation, laying the foundation for second-life applications.
Beyond pack operation, ALBATROSS also developed semi-automated dismantling and recycling solutions, ensuring that materials and components can be recovered safely and efficiently. Eco-design principles and LCA were integrated from the beginning, guiding technical decisions to maximise sustainability and circularity throughout the development process.
Quantifiable achievements include:
Weight reduction: A Decrease in module weight of 13.1% is achieved; however, total battery system weight is increased by around 16%.
Energy density: 259 Wh/kg at cell level and 210 Wh/kg at the module level, with potential to reach ~230 Wh/kg under mass production conditions.
Thermal management: < 3 °C temperature gradient between cells achieved through immersion cooling and integrated sensors.
Charging performance: 2.5× faster charging demonstrated with the Anode-Controlled Charging algorithm.
Circularity: > 90 % material recovery at module level; > 80 % cathode metal recovery (Li, Ni, Mn, Co) with > 93 % purity.
Lifetime: Cell-level degradation models confirmed battery durability of up to 300,000 km with > 80 % SoH under optimal thermal control (25 °C).
Environmental performance: LCA results show a 24.3 % reduction in CO2 impact compared to the BMW i3 baseline.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The design and manufacturing of the battery modules were completed after several optimisation cycles. Early leakage issues led to improved joining and sealing strategies using laser welding, resistance spot welding, and adhesive bonding. Aluminium busbar joints were validated to ensure stable weld penetration and reliable electrical conductivity. The redesigned modules achieved structural and electrical integrity and reached TRL 6 readiness.
The structural battery tray was developed as a hybrid concept combining aluminium extrusion profiles, cast corner parts, and composite reinforcements. Advanced joining methods—FSW, CMT, laser welding, and hybrid adhesive bonding—were validated to ensure sealing and crash performance. Full-scale demonstrators achieved all mechanical targets, confirming industrial feasibility at TRL 6–7.
An AI-based Battery Management System (BMS) and an advanced partial-immersion cooling system (TMS) were validated through simulations and laboratory tests. The BMS detected potential failures 35 minutes in advance, achieved a State-of-Health RMSE of 0.0033 and proved scalable up to 800 V. The hybrid thermal system, combining immersion cooling, loop heat pipes, and printed heaters, maintained temperature differences below 3 °C, improving safety and fast-charging efficiency. Both subsystems reached TRL 6.
A semi-automated dismantling process achieved ~90% module separation and >80% recovery of metals with 93–95% purity. Re-synthesised cathode material retained 71% of the reference capacity, confirming circular recovery feasibility.
Life-cycle and sustainability assessments showed a 24% reduction in overall environmental impact compared with the reference system. A Knowledge-Based Engineering (KBE) framework was developed to link design parameters with LCA indicators, enabling eco-design and data-driven decision-making across the product life cycle.
Three main Key Exploitable Results (KERs) were defined:
KER 1 – Battery Modules and Trays: Lightweight aluminium structures and validated joining technologies ready for industrial implementation. The developed tray concept supports serial production and European leadership in cost-effective lightweight battery enclosures.
KER 2 – Battery Management System: Modular, AI-enabled BMS providing early failure prediction and 25% shorter charging times. The system is ready for commercialisation as a configurable product or integrated pack solution, supporting digital fleet management and predictive maintenance services.
KER 3 – Thermal Management System: Hybrid cooling and heating technology ensuring <3 °C temperature variation and efficient operation under fast-charging and low-temperature conditions. Scalable for both EV and stationary applications, the system is being prepared for industrial deployment and future EU demonstrators.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Across its five expected impacts, ALBATROSS achieved major technological progress and advanced well beyond the state of the art.
Lightweight and performance:
Energy density reached 259 Wh/kg at cell and 210 Wh/kg at module levels, exceeding expectations. Full pack lightweighting was limited by safety and sealing requirements of the immersion-cooling system, leading to structural reinforcements and a modest weight increase versus the OEM reference. Nevertheless, the project demonstrated the successful integration of lightweight, crash-resistant, and thermally stable designs at system level.
Fast charging and range confidence:
The target of 25 % shorter charging time was achieved using high-energy cylindrical cells and the Anode-Control Charge algorithm, enabling safe 30-minute charging at 150 kW and directly addressing user concerns over range and convenience.
Extended lifetime:
Although full pack validation for 300,000 km could not be completed, cell-level tests and degradation models confirmed that this target is attainable under optimised 25 °C conditions, proving that advanced thermal management is essential for long-term durability.
Circularity and sustainability:
ALBATROSS exceeded its 20 % circular-economy goal, achieving an average 24 % reduction in life-cycle impact and, under PV-based energy, more than 60 % improvement, demonstrating strong synergy between lightweighting, recyclability, and renewable-energy use.
Sensorisation and intelligence:
The integration of printed sensors, modular electronics, and AI-based BMS algorithms enabled temperature monitoring at up to 768 points, creating a new benchmark for diagnostic precision and predictive safety.
Beyond technical outcomes, ALBATROSS strengthens Europe’s industrial competitiveness and supports job creation in advanced manufacturing, digital energy, and recycling. The project contributes to transport decarbonisation, boosts public trust in EVs, and promotes skills development through workshops and European qualification schemes—helping build a greener, smarter, and more sustainable mobility ecosystem.

ALBATROSS module approach

Final battery pack design of the ALBATROSS