Projects › Engineering Management
Repurposing End-of-Life EV Batteries for Micro-Mobility
Role:Project Manager & Lead Analyst (Production & Market)Year:2025Type:Course Project
Automation adds only $0.04/unit vs. manual at 50,000 packs/yearRepurposed scooters captured 65-91% of simulated market shareIdentified labor and equipment as primary cost driversHigh consumer price sensitivity (WTP +$42 for range, +$32 for new)
Theme: Quantitative Entrepreneurship
Projects › Engineering Management
Repurposing End-of-Life EV Batteries for Micro-Mobility
Role:Project Manager & Lead Analyst (Production & Market)Year:2025Type:Course Project
Automation adds only $0.04/unit vs. manual at 50,000 packs/yearRepurposed scooters captured 65-91% of simulated market shareIdentified labor and equipment as primary cost driversHigh consumer price sensitivity (WTP +$42 for range, +$32 for new)
Problem & Users
Evaluated the feasibility of using automated disassembly to repurpose end-of-life (EoL) EV batteries for micro-mobility. This addresses the high cost of new batteries and consumer concerns about the performance of reused components.
Executive Snapshot
- Disassembly Process: Modeled the 4-stage, 36-sub-step disassembly flow for Chevy Bolt battery packs. This process breaks the pack down to the cell level for health assessment and sorting.
- Production Cost Model: Developed a process-based cost model comparing manual vs. automated disassembly. At 50,000 packs/year, the automated unit cost ($0.95) is nearly identical to manual ($0.91), with labor and equipment as the primary cost drivers.
- Market & Demand Analysis: Conducted an MNL model analysis showing high price sensitivity. While consumers are willing to pay more for new batteries (+$32) and range (+$42), the lower price of repurposed scooters allowed them to capture 65-91% of the simulated market.
- Key Decisions Modeled: Analyzed the economic impact of key strategic choices, including the battery pack origin, the level of disassembly (module vs. cell), and the degree of automation.
Jobs to be Done
- • Provide longer-range micro-mobility options at an affordable price.
- • Offer a sustainable, eco-conscious option using second-life technologies.
- • Create an economical battery replacement path for high-end scooter owners.
Decision Framework
Battery Pack OriginThe make and model of the donor vehicle. Assumed to impact acquisition cost and final product pricing.
Level of DisassemblyDisassembling to the cell-level (vs. module) allows for cell sorting, which could enable higher performance and warranties for the final product.
Degree of AutomationThe key economic trade-off: too little automation doesn't reduce labor costs, while excessive automation leads to prohibitively high equipment costs.
Current Status
Final recommendations include: 1) Automating the initial battery pack safety assessment to reduce labor costs; 2) Targeting the high-performance market where price-to-performance is key; and 3) Scaling to >100,000 units to achieve economies of scale.
Theme: Quantitative Entrepreneurship