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Full-Service Lifecycle Management for Electric Vehicle (EV) Batteries

We provide comprehensive support throughout the entire lifecycle of an EV battery. The Dynamic Team consists of experts in the Closed-Loop Economy of EV Batteries—an economic model that eliminates waste by ensuring everything is repaired, remanufactured, repurposed, or recycled.

As part of this process, we offer EV battery testing to guarantee performance, safety, and reliability at every stage of the battery’s life cycle.

Based in suburban Chicago, we are a leading remanufacturer of automotive drivetrain components and systems. Staying at the forefront of electric vehicle technology, we continue to expand our capabilities to include electrified drivetrain systems. Our latest expansion is dedicated to supporting the complete lifecycle of electric vehicle batteries.

Electric Vehicle (EV) Battery Lifecycle

Electric vehicle (EV) batteries have a finite life. Over time, the originally installed EV batteries will no longer meet the power and energy demands of the vehicle manufacturer and need replacement. Through remanufacturing, we can bring them back to the OES specification.

When a battery can no longer be remanufactured to OES specifications there can be repurpose options. Secondary applications, such as energy storage systems and stationery back up power systems, can help maximize the total life-time value of each battery.

When the battery capacity is no longer acceptable in the secondary application, they reach the end of their lifecycle and must be disposed of responsibly. We have third party vendors to ensure proper environmental disposal.

OUR BATTERY SERVICES

INSPECTION

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We disassemble packs as defined by the original equipment manufacturer. Each module is visually inspected to ensure it is within specification.

TESTING

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We provide one-on-one support for each customer to help define testing conditions for performance verification including capacity, stress and cycle life. Our engineering team develops custom scripts per customer specified requirements and is available to provide additional guidance and expertise.

REMANUFACTURING

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We verify products through our multistep process. Each module is cleaned and re-inspected prior to testing. After testing is completed, a detailed analysis report is generated and included with each reassembled battery pack.

REPURPOSING

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We provide alternative options for batteries that no longer meet OES automotive specifications. Applications such as energy storage systems and stationery back up power systems can help maximize the total life-time value of each battery.

STORAGE & MAINTENANCE

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We store and maintain each battery pack within our secure
onsite warehouse. Scheduled activities are conducted to
maintain required state of charge.

RECYCLING

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We provide disposal services for batteries that are damaged, unrepairable or have reached end of life status. We have established partnerships with reputable recyclers to ensure proper handling and processing.

Electric Vehicle (EV) Battery Testing

As an established automotive remanufacturer, we can provide considerable expertise and knowledge in various battery module and pack level testing services. Working together with our dedicated electrification team, our engineers will collaborate with your team to create a suitable test plan. Our process for testing ensures that the final product meets the maximum level of quality and reliability as defined by the Original Equipment Manufacturer (OEM).

Dynamic provides one-on-one support to customers by helping develop customized test programs to support their individual testing needs. We create custom test scripts and provide additional guidance and expertise for EV systems and components. Utilizing advanced EV battery testing equipment, we offer a comprehensive range of testing procedures, including battery safety testing, to help estimate the overall battery State of Health (SoH). Some of these tests and services include:

  • Open Circuit Voltage (OCV) Measurement and Recording
  • Life Cycle, Characterization, and Performance Testing
  • Battery Management System (BMS) Validation
  • Low and High Discharge Rate Testing
  • CAN Bus Communication and Control
  • Temperature Monitoring and Control
  • R&D Battery Pack Design
  • Module and Pack Cycling
  • Development Testing
  • Consulting Services
  • Validation Testing
  • Thermal Imaging
  • Load Testing
  • Environmental Testing

Logistics Management

Our team delivers the highest standard of shipment care to mitigate en-route risks. Our specialized shipping and receiving department is DOT 49 Code of Federal Regulations (CFR) Hazmat Certified to help customers understand packaging and documentation requirements. The final product is identified with hazard labels including but not limited to appropriate UN shipping labels and other required markings to adhere to regulatory standards laid out by all governing bodies at both the regional and international level.

Our Battery Test Facility

Our Battery Test Facility consists of 6 Electric Vehicle (EV) battery test systems and their supporting framework. Our test management software and Data Acquisition Unit (DAQ) continuously collect, timestamp, and archive temperature measurements. For thermal management, we also operate a standalone glycol chiller system with custom-designed liquid cold plates for Units Under Test (UUT). Our facility is equipped to support lithium ion battery safety testing, ensuring reliability and performance during critical evaluations.Utilizing this equipment and software, we can provide our customers with full-service turnkey operations for Remanufacturing, Repurposing, Logistics Management, and Recycling.

Battery Performance Testing

2x NHR 9300 units for Pack Level Testing

Electrification and battery performance testing

4x NHR 9200 units for Module Level Testing

Walk in Environmental Test Chamber

FAQS

What is the Typical Battery Life Cycle?

The typical life cycle of lithium-ion cell in an electric vehicle battery pack consists of the following steps:

  1. A battery cell manufacturer produces cells and conducts initial cycling.
  2. The battery cell OEM then ships cells to a battery pack assembler or manufacturer.
  3. The battery pack assembler or manufacturer combines cells into various combinations, adds protection electronics and controllers,  and case materials suitable for its intended application.
  4.  A distribution center sells, and potentially ships the device containing a battery pack to a customer.
  5. The customer uses the device containing a manufactured battery pack.
  6.  At the device end of life or battery pack end of life, the device or battery pack is discarded.
  7. The battery pack is transported to a solid waste disposal site or to a recycling site.

Must Read: Unveiling The Lifespan Of Electric Car Batteries: How Long Do They Truly Last?

Why Is There a Need for Battery Testing Facilities?

When an EV battery reaches the end of its useful first life cycle in an automotive application, on average, it still has around 80% – 70% of its original storage capacity. Instead of transporting these packs to a recycling center, they can be repurposed into second-life applications such as stationary power sources. By reusing EV batteries, we can decrease the demand for further battery production and minimize landfill waste. Testing facilities such as Dynamic work hard to enable a closed-loop economy for EV batteries. Testing services we provide at Dynamic help prepare these batteries for safer use in their second life applications.

Are EV batteries reusable and/or recyclable?

EV batteries can be recycled and reused, reducing the amount of lithium and other metals that would otherwise end up in landfills. Some projections suggest that by 2030, up to 90% of EV batteries could be recycled. While challenges remain, such as developing cost-effective recycling methods, the growing demand for EVs ensures that progress will continue. As we work towards a more sustainable future, repurposing or recycling EV batteries is just one important step we can take to reduce our impact on the environment.

Does EV have a transmission?

No, an electric motor does not require a transmission system. Unlike a combustion engine that needs a gearbox to assist with acceleration and deceleration, an electric motor generates maximum torque at low speeds and maintains it throughout the acceleration. Therefore, the absence of a gearbox simplifies the vehicle design and makes EVs perform better than their conventional counterparts.

WHY DYNAMIC MANUFACTURING?

Dynamic Manufacturing is a leading automotive drivetrain component and system remanufacturer located in suburban Chicago. We remain at the forefront of the manufacturing industry through electrification advancements that give you expanded services in electrified drivetrain systems, battery life cycle, and other EV technologies.As demand grows in the battery safety testing services market, we continue to strengthen our capabilities to support evolving safety and performance standards for electric vehicle components.Our expertise and facilities position us among the trusted EV battery testing companies serving the growing needs of the industry.

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