While electric vehicles (EVs) are becoming more popular worldwide, questions remain on what will happen with these vehicles when they reach their end-of-life and how will we then recover the valuable components, such as the permanent magnets used in EV motors. These magnets, located in rotor assemblies, enhance power efficiency but also contain large amounts of critical raw materials (CRMs). However, they are notoriously difficult to remove and recycle,
To address this, KU Leuven’s Life Cycle Engineering research group has partnered with the European Commission’s Joint Research Centre (JRC) to find better ways to disassemble EV motors and recover the CRMs from their magnets. Their research contributes to the JRC’s 2025 report, which provides scientific evidence to support European policies aimed at improving the the circularity of CRMs in vehicles.
Improving EV motor disassembly for a better CRM recovery
The JRC and SIM2 KU Leuven collaborated to make EV motor disassembly more efficient, aiming to improve rare earth metal recovery and strengthen the EU’s recycling value chain. As part of the study, KU Leuven analyzed two EV motors—one from Toyota and one from Mazda. They then adapted their existing methodology for assessing human-robot cooperative disassembly to fit EV motors. Using Visual Components software, they simulated a human-robot disassembly process and calculated how long a robot would take to remove key components. By combining these time estimates with real-world disassembly experiments in KU Leuven’s Re- & Demanufacturing Lab, researchers identified the biggest challenges in dismantling EV motors.
The study identified several ways to improve EV motor design to make disassembly easier and enhance the recovery of reusable components, valuable materials, and CRMs in a more cost-effective way. To address these challenges, researchers proposed several circular design guidelines for EV motors:
• Fixed and known locations for components and connectors: For example, the Toyota motor’s cable plugs are securely positioned on a rod, making them easier to locate and remove.
• Fixed and known component locations: For example, in the Toyota motor, cable plugs are securely positioned on a rod, making them easier to find and remove.
• Standardized connectors: Cable plugs should be designed for easy removal using a simple two-finger parallel gripping mechanism, a common and cost-effective solution.
• Consistent screw types and sizes: Using the same screw type, at least within a single component, simplifies disassembly.
• Easily accessible screws: Screws should have enough clearance for easy removal with a ratchet wrench.
• Designed tool access points: Components with high-precision fits should include designated access points to simplify removal.
By applying these design principles, manufacturers can make EV motor disassembly more efficient, improve material recovery, and support a more sustainable circular economy. This is especially important as the industry moves toward Industry 4.0, where robots will play an increasingly significant role.
Strategies for recycling rare earth permanent magnets
Along with improving disassembly, the research explored three key strategies for recycling of rare earth magnets:
1. Direct reuse – Demagnetizing and reusing old magnets is effective, but brittleness and hidden defects can limit their reliability.
2. Alloy recycling – Using hydrogen to break down magnets into reusable powder is a cost-efficient and eco-friendly method, though coatings can interfere with the process.
3. Elemental recycling – Extracting rare earth elements in high purity offers flexibility but is more expensive and resource-intensive.
Since no single method is ideal, the study emphasizes the need for a combined approach to maximize recovery while balancing costs and environmental impact.
Sustainability and competitiveness for the automotive industry
The research at the Re-& Demanufacturing Lab of KU Leuven targets to support the European automotive industry to become more sustainable and self-sufficient. Rare earth materials are essential for e-mobility, but they are scarce and critical due to Europe’s dependency on imports from other continents. By improving the recovery and reuse of these materials, a step is taken towards reducing dependence on mining and strengthening the EU’s position in the global market.
As part of the broader JRC report, different scenarios were assessed from material, environmental, economic, and social perspectives, highlighting synergies that enhance circularity and resource efficiency. Efficient disassembly and smarter recycling strategies don’t just benefit the environment; they also create new business opportunities. Recovering valuable materials from end-of-life EVs can support a thriving market for secondary raw materials, opening doors for innovation, for example in repurposing and remanufacturing. SIM2 KU Leuven’s findings provide European Union with practical solutions to keep critical materials in the loop, therefore contributing to a more resilient and competitive industry.
Acknowledgement
This work was part of a broader collaboration that also involved researchers from Università di Bologna and Politecnico di Milano, each contributing their expertise to different aspects of the project. This research is set up in the support of the new End-of-Life Vehicle Regulation proposal (ELVR) 2023/0284/EC and the Critical Raw Materials Act (EU) 2024/1252
To read the JRC report, click here.
About the author: Dr. Núria Boix Rodríguez is a postdoctoral researcher in the Life Cycle Engineering group at KU Leuven. Her research specializes in life cycle engineering and eco-design, aiming to enhance product sustainability and extend their lifespan.
