D2.2 - Report on Design-for-eXcellence

This document outlines the pathway towards an optimized design of a battery pack with regard to improving material and energy efficiency during production, use and end of life. The goal is to increase the durability of the materials and components and to make it easier to recover and recycle them, in line with eco-design practices and standards. The Lean Design-for-X (LDf-X) methodology was used to identify areas for potential improvement in the pack's design, which will support the design decision-making process in Task 2.1. The LDf-X methodology encompasses 4 main pillars that aim to assess the design effectiveness and efficiency of the battery pack underdeveloped within the project. The EXTENDED project aims to assess the domains of Design-for-Manufacturing, Design-for-Secon Life, and Design-for-Recyclability. The results reveal consistent opportunities to enhance the efficiency of control, safety, mechanical, and electrical systems across different domains. Key areas for improvement that would significantly boost overall system performance include reducing weight, optimizing coolant flow, and speeding up disassembly and assembly processes.