Stellantis-Marbel battery: cheaper and more sustainable

A European research project has unveiled a new battery design that could help electric vehicles become more sustainable, easier to recycle, and cheaper to repair. The battery, developed under the EU-funded Marbel project and backed by Stellantis, has been created with circular economy principles in mind. As such, it also aims at finding a second life beyond the road.

The project, coordinated by Catalonia’s Eurecat Technology Centre, focuses on building a battery that is easier to take apart, uses fewer raw materials, and can handle ultra-fast charging. It also features innovative technology capable of monitoring its health and predicting when it’s nearing the end of its useful life.

Modular is easier

At the heart of the prototype is a simple but powerful idea: modularity. This means that the batteries can be assembled and disassembled with standard tools, repaired more easily, and repurposed when they’re no longer fit for cars.

Additionally, each pack contains up to 60% recycled aluminum, saving an estimated 777 kilograms of carbon emissions per unit. The result, its developers say, is a battery designed not just for performance but for longevity.

“The focus on circularity creates a pathway to more sustainable electric vehicle technology,” said project coordinator Eduard Piqueras. “At the same time, by optimizing battery performance, we address the main hurdles that hinder electric vehicle acceptance and adoption, such as limited range and lengthy charging times.”

Switching between 400 or 800 volts

The battery’s internal architecture has been redesigned to allow faster charging while managing heat more evenly—a key barrier in ultra-fast charging. Its electrical system can automatically switch between 400 and 800 volts, depending on the type of vehicle it’s powering.

But the Marble project goes further, building in intelligence from the start. Each battery cell includes a small electronic manager, controlled by Bluetooth, that monitors its condition and communicates wirelessly with a central system.

Together, they feed into a digital twin—a virtual replica of the battery that uses artificial intelligence to analyze performance, wear, and tear and predict how long it will last.

Domestic use

This opens the door to new uses once the battery is no longer viable for cars. Violeta Vargas, a researcher at Eurecat, says the project was designed with second-life applications (reusing batteries in energy storage for homes or industry) as the end game. “We’ve extended battery usage while maintaining material value,” she said.

The Marbel system simplifies recycling at the end of a battery’s life. The researchers say they can easily recover high-purity raw materials, including lithium, cobalt, and nickel, in high demand as electric vehicle production ramps up across Europe.

The project, backed by the EU’s Horizon 2020 program, brought together 16 partners from eight countries—including universities, engineering firms, small businesses, and – as mentioned – the carmaker Stellantis, betting high on circular models for car production and reuse.

The company is currently speeding up its Sustainera hub in Turin for reusing components. At the same time, the EU is tightening rules on battery sustainability, aiming to reduce reliance on imported raw materials and cut emissions across the automotive supply chain.