SciTransfer
Predictive Battery Analytics · Project

AI-Powered Digital Twins for Battery Life Extension and Second-Life Resale

transportMarket-readyTRL 9

Imagine if you could know exactly how much life is left in every single cell of a used car battery. Instead of throwing the whole thing away, this tech acts like a health scan to find the strong parts and group them together. It's like sorting old Lego sets to build a new, smaller kit that still works perfectly for a different job.

By the numbers
1,525 GWh
Annual battery demand by 2030
99%
Reduction in superfluous resource waste
4
Times faster battery health calculations via digital twin
70-80%
Percentage of Li-ion batteries still usable after first use
The business problem

What needed solving

Automotive OEMs face high costs and safety risks because they cannot predict the remaining life of used batteries, turning 70-80% of usable batteries into expensive industrial waste.

The solution

What was built

An analytic software platform and digital twin ecosystem that calculates battery health, capacity, and remaining cycles at the module level.

Audience

Who needs this

Electric Vehicle ManufacturersBattery Pack AssemblersEnergy Storage System OperatorsBattery Recycling Companies
Business applications

Who can put this to work

Automotive
enterprise
Target: Electric Vehicle OEM

If you are an Automotive OEM dealing with the high cost of battery disposal and negative residual value — this project developed predictive analytics software that calculates remaining capacity and health. This allows you to re-pack batteries and turn industrial waste into assets with resale value.

Energy Storage
any
Target: Stationary Battery Operator

If you are a battery operator dealing with unpredictable battery degradation — this project developed digital twin technology that monitors health in real-time. This allows you to adapt battery usage to their actual state of health and remaining lifetime.

Waste Management
mid-size
Target: Battery Recycling Firm

If you are a recycling firm dealing with massive volumes of Li-ion waste — this project developed a method to identify usable modules. This eliminates the superfluous waste of resources by nearly 99%.

Frequently asked

Quick answers

How does this reduce the cost of battery disposal?

It transforms batteries from a waste expense into a commercial asset by predicting remaining charge cycles and capacity, allowing for re-packing and resale.

Can this be scaled for the expected 2030 battery demand?

The software is designed to handle the projected demand of 1,525 GWh annually by 2030 through automated analytics and digital twin technology.

What is the IP or licensing model for this software?

Based on available project data, the specific licensing terms are not disclosed, but the solution is developed as an analytic software platform by TWAICE.

How does it integrate with existing battery hardware?

The system uses digital twins to monitor batteries and perform health calculations up to four times faster than traditional tests.

What is the timeline for implementing this in a production line?

The project period ran from 2022-10-01 to 2024-09-30, suggesting the core technology is now developed and ready for application.

Consortium

Who built it

The project is led by a single SME, TWAICE Technologies GmbH, with a 100% industry ratio. This lean structure indicates a highly focused commercial drive, avoiding academic delays and prioritizing a direct path to market deployment.

How to reach the team

Contact TWAICE Technologies GmbH in Germany for licensing and integration inquiries.

Next steps

Talk to the team behind this work.

Contact our analysts to explore integrating TWAICE predictive analytics into your battery value chain.

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