Altilium and Jaguar Land Rover (JLR) have showcased the UK’s first electric vehicle battery cells made from recycled cathode and anode materials. The demonstration took place at the Cenex Expo 2025 and marks a step forward in building a circular economy for EV batteries.
The partners displayed new automotive-grade NMC 811 multilayer pouch cells. These were manufactured with cathode active material (CAM) recovered from end-of-life EV batteries using Altilium’s EcoCathode process.
The concentration of recovered CAM already meets the 2036 recycled content targets under EU battery regulations.
Initial testing showed performance comparable to conventional materials. JLR is now conducting full validation studies at its advanced battery testing facilities.
Alongside the multilayer cells, the partners also produced single-layer pouch cells with 100% recycled cathode and graphite anode materials.
Visitors at Cenex saw the cells integrated into a virtual reality model of the Jaguar I-PACE battery pack. JLR uses the same VR tools in its design programs.
Dr Christian Marston, COO and co-founder of Altilium, called the achievement “a major technical breakthrough and a vote of confidence in the UK’s ability to lead in battery recycling.” He added that the team is proving recycled materials can meet auto standards while cutting emissions and dependence on imports.
An independent Life Cycle Assessment by Minviro confirmed the environmental benefits. Using 100% recycled CAM for NMC 811 pouch cells in the UK could cut greenhouse gas emissions by 32% compared to cells made with virgin materials in Asia.
Other categories also showed major improvements: 30% less particulate matter formation, 58% lower freshwater ecotoxicity, and 38% reduced impact on metal and mineral resources.
Dr David Sellick, JLR’s project lead, said: “This project reinforces JLR’s leadership in sustainable innovation, marking a significant step forward in reducing the environmental impact of the largest contributor to an EV’s carbon footprint – the battery cell.” He added that the initiative shows performance and sustainability can work together.
Altilium’s EcoCathode process recovers more than 95% of cathode metals and over 99% of graphite from battery waste.
The recovered metals are upcycled into high-nickel CAM, while graphite undergoes further purification for anode production.
The project has support from the Advanced Propulsion Centre UK under its Advanced Route to Market Demonstrator program. It also helps UK manufacturers align with upcoming EU rules on recycled content in EV batteries.
Scaling up in the UK
The Cenex showcase builds on trials earlier this year where Altilium produced lithium-ion cells with its recycled NMC 811 CAM. Those tests already showed performance equal to cells made from primary mined materials.
Altilium recently opened ACT 2, the UK’s first commercial EV battery recycling plant, in Plymouth.
The company is now developing ACT 3, a large-scale facility expected to recover battery minerals from up to 24,000 vehicles each year.
By partnering with JLR, Altilium aims to secure a domestic supply chain for recycled materials while ensuring that UK-built vehicles comply with EU regulations.