Optimized Li-rich Co-free cathodes deliver a high discharge capacity of 250 mAhg-1, fast charging at 3C, and capacity retention of 65% after 800 cycles. Cathode water processing yielded results comparable to NMP-based processing. Silicon samples were recycled from different sources and tested as composite anode with graphite. Optimized anodes deliver 650 mAhg-1 at C/3 and 438 mAhg-1 at 3C. Several compositions with LiFSI salt and (flame-retardant) additives were formulated and tested as electrolytes, leading to a more stable SEI formation for the anode. Best-performing compositions, including ionic liquids, were formulated as a polymer electrolyte and implemented into coin cells. Selected battery cell components were upscaled and implemented into prototype pouch cells of 23 Ah for characterizations and module assembly; this was achieved by combining optimizations during processing with studies on voltage range, capacity ratio, and cell activation at full cell coin cell level. Cell assembly was conducted using a semiautomatic cell production line, which allowed manufacturing developments to be implemented, including thinner current collectors and the integration of smart sensors for improved safety. The fabrication steps, electrolyte filling and formation, were also optimized during the project. BMS innovations, including integrating sensors, wireless communication, and advanced models and algorithms, have been developed and validated at the battery pack level. The pack designed has sustained 3C charging rates, and prototype COBRA pouch cells have shown higher voltage windows than current generation 3 solutions. The battery pack fabrication included light and strong components with green and recycled materials, and its design targets easy battery disassembly for 2nd life: the pack sustained fire for more than 30 min., and a weight reduction higher than 50 % to steel with better tensile strength per kg. Testing activities were defined according to market needs and electric vehicle standards to validate the battery packs. Environmental and sustainability studies have demonstrated that the recyclability of the battery pack would be 95 %. The use of Co has been completely avoided, showing improvement in LCA and SLCA impacts. In terms of cost, considering the entire lifecycle, the price of the final battery pack was reduced by 33 % compared to the benchmark. The COBRA consortium has published over ten open-access journals, participated in 47 events, and released the Market Intelligent reports, greatly impacting the battery community. The partners are exploring several exploitation pathways, including business case support and continued research in future projects.
