SAFELOOP advances safer and more sustainable EV batteries
The SAFELOOP project focuses on building safer, cleaner, and higher-performing lithium-ion batteries for electric vehicles in Europe. The project supports the EU goal of climate neutrality by 2050 while strengthening the regional battery supply chain.
SAFELOOP stands for Securely Advancing Future EVs with Li Ion batteries through Optimized Pathways. It is a 36-month initiative that started in June 2024. The project brings together 15 partners from 11 countries. Funding comes from Horizon Europe, with five million euros awarded by the European Commission.
Rising demand for reliable energy storage
Demand for energy storage is growing fast. Society depends more on renewable energy, electric transport, and mobile power systems. As a result, batteries must deliver higher performance while remaining safe and durable.
Global EV battery demand is expected to reach 735 GWh by 2025. By 2033, more than 125 million electric vehicles could be on the road. Therefore, battery safety and sustainability can no longer be optional.
SAFELOOP responds to this challenge by improving how EV batteries are designed, built, and recycled. The project aims to raise safety standards while cutting environmental impact.
Focus on recycled and European materials.
A core goal of SAFELOOP is to use recycled raw materials sourced within Europe. This approach reduces reliance on imports and lowers supply chain risk.
The project develops key battery components, including anodes, cathodes, separators, and electrolytes. Partners combine these parts into battery packs designed for electric buses. As a result, SAFELOOP links research directly to real-world mobility use.
By doing so, the project supports Europe’s plan to build a strong and independent battery industry.
Advanced cathode and anode development
SAFELOOP prepares cathode materials such as NMC and LFP using both primary and recycled sources. In addition, the project develops lithium manganese metal oxide cathodes as an innovative option.
Researchers test electrochemical performance using coin cells and pouch cells. At the same time, they add engineered carbon materials to improve cycling life and safety.
On the anode side, SAFELOOP creates a composite material that blends natural graphite, recycled graphite, synthetic graphite, and nano silicon. This design increases energy density and improves stability. The target is 2,000 cycles while retaining 80 percent of the initial capacity.
Safer separators and improved electrolytes
Separator safety plays a critical role in battery reliability. SAFELOOP qualifies separators coated with nanoscale alumina. These separators range from 15 to 25 microns in thickness and use polyethylene and polypropylene. Silica-filled separators are also under evaluation.
In parallel, the project designs non-flammable liquid electrolytes. These electrolytes work with recycled anodes, cathodes, and separators. Through targeted additives, the team improves cycling stability by 15 percent compared to 2019 benchmark cells. At the same time, flame resistance improves significantly.
Pouch cell testing and performance validation
SAFELOOP develops two-ampere-hour pouch cells using the newly developed materials. Researchers optimize technical parameters during electrode development.
Safety testing includes flash point analysis and self-extinguishing time measurements. Tests take place at the electrolyte level and the cell level. This ensures reliable safety data before scaling up.
Safety across the full battery life cycle
Battery safety remains a central theme throughout the project. SAFELOOP evaluates how new materials affect the full battery life cycle. This includes use in battery packs, transport, performance aging, disassembly, and recycling.
The project compares three SAFELOOP cell versions with current-generation EV cells. These cells undergo testing under electric bus conditions. Tests include road trials, charge-discharge cycles, and performance assessments.
In addition, SAFELOOP improves safety at the battery management level. The project enhances cell sensing and guides integration into EV battery management systems.
Preparing for gigafactory-scale production
SAFELOOP also addresses cost and scale. The project studies battery pack economics and reviews patents related to lithium-ion battery recycling in Europe.
Value chain mapping, eco design rules, and environmental and social assessments support future commercial use. Together, these efforts help move recycled batteries toward gigafactory production.
Strong European partnerships
SAFELOOP contributes actively to the BATT4EU partnership and the Battery 2030 plus initiative. These networks promote innovation in battery materials, manufacturing, and recycling across Europe.
The project also works closely with related initiatives such as INERRANT and SAGELi. Through these links, SAFELOOP increases impact and avoids duplication.
A step toward safer European EV batteries
By combining research expertise with industrial experience, SAFELOOP sets a clear path toward safer, greener, and more competitive EV batteries. The project aims to deliver longer battery life, higher safety standards, and improved recycling rates. In doing so, it supports Europe’s transition to clean mobility and energy independence.
