This project is aimed at developing and demonstrating a novel multi-material lightweight design for easy assembly and reversable manufacturing of EV battery packs for easy assembly and disassembly for…

The Department of Energy Advanced Research Projects Agency awarded a $3.214 million Cooperative Agreement to the Regents of the University of Michigan on April 8, 2026, for research and development of multi-material direct joining and un-joining techniques to enable easy assembly and disassembly of electric vehicle battery packs while maximizing circular reuse. Work is performed in Ann Arbor, Michigan, through April 7, 2029.

The project develops novel dissimilar-materials joining methods—including direct welding of polymer composite to metal, aluminum alloy to steel, and aluminum to copper—to replace traditional assembly processes such as fusion welding, adhesive bonding, and mechanical fastening. The research focuses on cell-to-module and cell-to-pack assembly architectures that facilitate reversible manufacturing and non-destructive disassembly, with emphasis on efficient separation of target components rather than complete package deconstruction.

The award funds research under ARPA-E's Catalyzing Innovative Research for Circular Use of Long-Lived Advanced Rechargeables (CIRCULAR) program (CFDA 81.135), which supports high-potential energy technologies too early for private-sector investment.

The University of Michigan passes through funding to The Pennsylvania State University as a sub-recipient. Penn State, through expertise provided by Dr. Jingjing Li in dissimilar material joining and welding metallurgy, supports research on laser-cutting and non-destructive welding separation methods for pouch-pack battery cells with thin metal tabs, addressing mechanical and thermal damage limitations in current separation approaches.

This project is aimed at developing and demonstrating a novel multi-material lightweight design for easy assembly and reversable manufacturing of EV battery packs for easy assembly and disassembly for achieving maximal circularity. Some of the recently developed novel dissimilar materials joining techniques by the project team members, e.g., direct welding of polymer composite to metal, aluminum alloy to steel or aluminum to copper, are the key enabler for transforming today's traditional joining and assembly processes (e.g., fusion welding, adhesive bonding, and mechanical fastening) to direct joining and unjoining of dissimilar materials.