The EV life cycle begins with the extraction of raw materials such as lithium, cobalt, nickel, and rare earth elements—key components for electric motors and lithium-ion batteries. This stage carries significant environmental and social implications, often involving energy-intensive processes and complex supply chains. With increased demand for these materials for a wide range of products, concerns over ethical sourcing and environmental damage have grown, prompting research into alternatives and recycling initiatives.
Battery production is one of the most resource-intensive elements of EV manufacturing. The high carbon footprint of battery production underscores the importance of recovering materials at end-of-life and feeding them back into the production cycle.
EV manufacturing largely mirrors that of internal combustion engine (ICE) vehicles, with added complexity due to battery integration, high-voltage systems, and additional cooling requirements. Key differences include the need for specialised components such as power electronics, inverters, electric motors, and large-capacity energy storage systems.
As OEMs aim for sustainability, many are designing vehicles with end-of-life considerations in mind—such as modular battery packs, easily accessible components, and clearly marked high-voltage wiring—to facilitate easier dismantling and material recovery.
The operational life of an EV is where it delivers its most significant environmental benefit—zero tailpipe emissions and improved energy efficiency. However, vehicle range, battery degradation, and charging infrastructure remain challenges.
During this phase, routine maintenance is generally lower than for ICE vehicles, with fewer moving parts and no need for oil changes. However, high-voltage components require specialist training and precautions, and this sets the stage for the final and often overlooked life cycle stage: dismantling.
Once an EV reaches the end of its usable life—whether through age, damage, or obsolescence—it enters the dismantling and recycling phase. This is arguably the most crucial stage for achieving true sustainability and supporting the circular economy.
EV dismantling is far more complex and hazardous than traditional vehicle dismantling, primarily due to the presence of high-voltage (HV) systems, lithium-ion batteries, and sensitive electronic components. Proper dismantling requires:
- Initial Assessment and Risk Management
The vehicle is inspected for damage, particularly to HV components. Safety protocols are enforced to prevent electrocution, thermal runaway, or fire. This assessment determines the steps for safe HV disconnection and component recovery. - High-Voltage System Shutdown
Using manufacturer-specific procedures, trained technicians isolate and shut down the HV system. This often includes removing service disconnects, disconnecting 12V systems, and verifying zero voltage presence before working on any component. - Battery Removal
EV batteries are heavy, high-energy systems that must be handled with extreme care. Depending on the vehicle, batteries may be removed from under the vehicle or inside the cabin. Appropriate lifting equipment and insulated tools are essential, and technicians must wear PPE, including arc-flash protection. - Component Dismantling and Sorting
Once de-energized, other EV-specific components such as inverters, DC-DC converters, electric motors, and battery management systems are removed and sorted. These components have high reuse or recycling value and may be sent for refurbishment or material recovery. - Material Recycling and Waste Processing
EV dismantling yields ferrous and non-ferrous metals, electronics, plastics, and hazardous materials. Lithium-ion batteries may go through second-life applications (e.g., energy storage systems) or be processed by specialised battery recyclers to recover lithium, cobalt, nickel, and other critical minerals.
The safe and efficient dismantling of electric vehicles demands a high level of technical competence, particularly when working with high-voltage (HV) systems that pose significant risks to untrained personnel. Mishandling these systems can result in serious injury, vehicle damage, or environmental harm. As such, proper training and certification are essential for anyone involved in EV dismantling.
Salvage Wire is at the forefront of high-voltage vehicle training, offering a tiered program tailored specifically for the vehicle dismantling and recycling industry. These courses are designed to build competence and confidence across a range of roles, from workshop operatives to high-voltage battery technicians.
· Level 1: Awareness Training
Ideal for non-technical staff, this course provides a basic understanding of electric and hybrid vehicles, focusing on identification and general awareness of risks. Suitable for receptionists, drivers, and admin staff.
· Level 2: Vehicle Recovery and Handling
Aimed at vehicle transporters, first responders, and those handling vehicles on-site, this level teaches safe recovery, storage, and handling practices for EVs and hybrids.
· Level 3: Technician Training
Designed for workshop staff and dismantlers, this course delves into practical, hands-on training in safe isolation, fault finding, and removal of high-voltage components. Risk management principles are integrated throughout, empowering technicians to assess and manage hazards independently.
· Level 4: High-Voltage Battery Technician
The most advanced level, suitable for experienced professionals, focuses on battery removal, testing, and repurposing. It includes practical assessments and is aligned with international certification standards to ensure best practice.
All Salvage Wire training is delivered by experienced professionals and includes real-world scenarios and hands-on exercises. The courses are accredited or recognised by leading bodies such as the Chartered Institution of Wastes Management, and TÜV Rheinland, providing internationally respected qualifications.
By equipping technicians with the knowledge, skills, and certification they need, Salvage Wire is helping to raise professional standards and ensure that EVs are dismantled safely, legally, and sustainably, supporting both environmental goals and operational excellence in the industry. Full details of available training specifically produced for the global vehicle dismantling community can be found at https://www.salvagewire.com/training-courses
As the global EV fleet grows, so too does the need for a robust, safe, and sustainable dismantling infrastructure. OEMs, dismantlers, and governments must collaborate to develop clear guidance, design vehicles for disassembly, and invest in training and technology.
Dismantling is no longer a scrapyard afterthought—it is a vital component of the EV life cycle. Through responsible dismantling, we recover valuable materials, reduce environmental impact, and support a circular economy that underpins the future of mobility. The electric vehicle life cycle is a complex chain of processes, each with its environmental and operational implications. Among these, dismantling holds the key to closing the loop. It ensures that the resources used at the start of an EV’s life can be reclaimed and reused, reducing the need for virgin material extraction and supporting the sustainability goals that make EVs attractive in the first place.
