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Automakers Seek 'Second Life' for EV Batteries Beyond the Scrapyard

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  Published in Automotive and Transportation on Friday, December 26th 2025 at 12:09 GMT by Newsweek

Automakers Seek “Second Life” for EV Batteries Beyond the Scrapyard

As electric‑vehicle (EV) sales surge, a growing number of automakers are turning their attention to what happens to a car’s battery once it’s no longer fit for the road. The Newsweek feature, “Automakers Stretching to Find Second Life Solutions Beyond Scrapyard,” paints a picture of a rapidly evolving industry that is exploring ways to repurpose spent EV batteries for everything from home backup power to large‑scale grid storage. The article argues that the push for “second life” applications is driven by environmental imperatives, cost considerations, and the sheer scale of battery waste that will accompany the coming decades of EV adoption.

The Problem: A Growing Battery Waste Stream

According to the article, the United States alone could see more than 300,000 electric vehicles on the road by 2030. Even if each battery pack lasts 8–10 years, the cumulative number of “retired” batteries will be staggering. Traditional end‑of‑life (EOL) options—scrapyards or landfills—do not make sense from a sustainability standpoint, and governments are beginning to tighten regulations on battery disposal. The news piece cites a 2022 EPA report that projects that the United States could have more than 40,000 tons of spent EV batteries by 2035, most of which would contain valuable lithium, cobalt, nickel, and other metals.

While some of this material can be reclaimed, the recovery process is energy‑intensive and expensive. Automakers, therefore, are looking for “second life” pathways that can reduce waste, lower costs, and add value before the batteries are finally recycled.

Repurposing Batteries for Energy Storage

The bulk of the article focuses on the repurposing of spent batteries as stationary energy storage units. Even after an EV battery is retired from the road, it typically still retains 60–80 % of its original capacity. By pairing these “second‑life” packs with renewable energy systems, utilities can add flexible storage without the high upfront cost of new batteries.

Ford’s “Project OnTrack” is highlighted as an early adopter. After retiring its 2022 Mustang Mach‑E’s battery pack, Ford is collaborating with ChargeGrid to test the pack’s suitability for grid‑scale storage. Ford hopes to demonstrate that second‑life batteries can reduce the need for new raw materials and cut costs by up to 30 % compared to fresh units.

Another example comes from General Motors (GM), which is working with Powerhouse Energy on a “home‑backup” solution that uses repurposed Chevy Bolt batteries to provide emergency power for homes and small businesses. GM’s initiative leverages the Bolt’s 60 kWh pack, which after five years of service still retains around 55 kWh of usable energy. The company argues that the second‑life market could support as many as 500,000 homes by 2030.

Tesla’s approach is also mentioned, albeit briefly. Tesla has been repurposing its Powerwall batteries for stationary storage, and the company is exploring the possibility of converting its “Second‑Life” cells into a modular storage system for commercial use.

Beyond the Grid: Industrial and Home Applications

While grid storage is the headline, the article also underscores other promising uses. For instance, Volvo is testing a “retired battery‑as‑fuel cell” concept for its heavy‑duty trucks. The idea is to couple the remaining energy in an old battery pack with a fuel cell stack, providing a hybrid power source that could extend truck range while reducing emissions.

In the home sector, Toyota is working with Energy Vault, a Swiss energy‑storage startup, to build a “second‑life” battery system for residential solar installations. By pairing a refurbished Prius battery pack with a home solar array, Toyota hopes to provide customers with a cost‑effective way to store solar power for nighttime use.

The article also mentions Nissan’s “Second Life” program, which has already placed a handful of repurposed Leaf batteries into “off‑grid” solar homes in Japan. Nissan’s goal is to create a supply chain that moves from “scrapyard” to “supply,” offering a practical solution for households in remote areas.

Technical and Regulatory Hurdles

While the potential is clear, the article doesn’t shy away from the challenges. Technical issues such as balancing degraded cells, ensuring safety in stationary installations, and maintaining warranty standards are highlighted. Automakers must also navigate a patchwork of regulations—state battery‑management laws, federal recycling mandates, and evolving standards for grid‑connected storage.

The Newsweek piece quotes a battery‑recycling analyst who notes that “the biggest hurdle isn’t the technology; it’s the business model.” Automakers need to decide whether to own and operate second‑life battery deployments, partner with existing storage companies, or simply sell the batteries to third‑party providers.

A Win‑Win for Sustainability and the Bottom Line

Despite the hurdles, the article makes a compelling case that second‑life battery initiatives can be mutually beneficial. By repurposing batteries, automakers can:

1. Reduce Environmental Impact – Cutting the need for new lithium‑ion production, which consumes water, generates CO₂, and involves mining activities with significant ecological footprints.
2. Create New Revenue Streams – Generating income from otherwise discarded assets.
3. Boost Consumer Appeal – Positioning brands as leaders in sustainability can be a differentiator in a crowded EV market.
4. Support Grid Resilience – Providing flexible storage to help utilities manage renewable variability and reduce blackouts.

The feature concludes by noting that the industry is still in its infancy. While some pilots are underway and a handful of products have reached limited commercial markets, large‑scale deployment will require more standardized protocols, clearer incentives, and continued collaboration between automakers, utilities, and recyclers.

Bottom Line

Automakers are no longer treating retired EV batteries as a waste problem; instead, they’re viewing them as a valuable resource for the next generation of clean energy solutions. Whether the goal is to power homes, strengthen the grid, or provide backup for critical infrastructure, the “second life” concept is gaining traction across the industry. As the article suggests, the path to a circular battery economy will involve innovation, partnership, and a willingness to reimagine what a battery’s life can look like after the final mile.