Eco-design of EV battery packs: A parametric LCA model considering integration efficiency, compression system, and disassembly

Electric vehicle (EV) batteries are not intrinsically eco-friendly and therefore require eco-design considerations. A parametric Life Cycle Assessment (LCA) model was developed to evaluate the eco-design potential of EV battery packs and provide guidelines for designers. The model incorporates diverse cell formats and chemistries, pack designs, material choices, use-phase conditions, and recycling pathways. A global sensitivity analysis revealed that both the end-of-life allocation methodology and pack energy content significantly influence LCA outcomes. The model was applied to examine the effects of pack integration efficiency as a weight reduction strategy, flexible compression as a means to extend lifespan, and design-for-disassembly as a method to minimize end-of-life treatments and improve material recovery rates. The results demonstrate that an optimized cell-to-pack strategy can reduce environmental impacts by 12–45%, a flexible compression system by 5–7%, and design-for-disassembly followed by direct recycling can decrease the environmental burden of battery packs by 3–45%.