Optimizing dismantling approaches for recycling of li-ion batteries: Strategies, challenges and economic analysis

Lithium-ion batteries (LIBs) are widely used in electric vehicles, consumer electronics, and energy storage systems due to their high energy density and long operational life. As demand for these batteries rises globally, their end-of-life management has become a growing concern due to environmental risks, material scarcity, and recycling inefficiencies. This review addresses the urgent need for safe, sustainable, and cost-effective dismantling practices, recognized as the most critical and preparatory step in LIB recycling, by evaluating current methods and proposing future directions. The review examines manual, mechanical and automated dismantling approaches, highlighting their respective advantages and limitations. Manual method offers straightforward material recovery but face safety, labour, and efficiency challenges. Emerging automated solutions using robotics, AI, and machine learning promise improvements in safety, scalability, and disassembly precision. In addition to dismantling strategies, the review discusses regulatory frameworks, environmental implications, and the importance of standardizing battery design for easier disassembly. It also provides future perspectives emphasizing automation, eco-friendly chemical processes, and public participation in battery collection. By organizing scattered knowledge and offering critical insights and recommendations, this review serves as a comprehensive resource for researchers, policymakers, and industry stakeholders. It aims to guide sustainable innovation and foster circular economy practices in LIB end-of-life management.