Global EV sales topped 14 million units in 2023, according to the IEA, putting mounting pressure on automakers to manage end-of-life batteries responsibly. Stellantis is positioning its SUSTAINera business as a response, expanding applications for high-voltage batteries beyond energy storage and into accessibility technology.
Its latest project, the AVATHOR ONE electric mobility device, illustrates how second-life batteries can intersect with inclusive design while extending asset value.
Developed by Turin-based startup Avathor, AVATHOR ONE is aimed at people who use wheelchairs or have limited mobility in non-road settings. The device runs on repurposed 15 kWh battery modules from Stellantis EVs, reconfigured by systems integrator INTENT S.r.l. into smaller 1.4 kWh and 2.8 kWh packs. These units include a bespoke battery management system to ensure performance and safety standards comparable to original automotive use. The project traces its roots to WheeM-i, an Italdesign concept unveiled in 2019, and was shown at Expo 2025 Osaka ahead of its presentation at Salone Auto Torino.
The collaboration reflects a tightly knit industrial cluster in northern Italy. SUSTAINera supplies tested end-of-life batteries from the Turin area, INTENT manages disassembly and re-packing, and Italdesign contributes engineering and product validation. This local supply chain lowers logistics costs and carbon intensity while retaining high technical control over battery quality—an important consideration as second-life applications diversify.
Beyond mobility aids, Stellantis is deploying second-life batteries in grid support systems. One example is ENEL X’s PIONEER installation at Rome Fiumicino Airport, which integrates repurposed packs into a storage plant designed to cut 16,000 metric tons of CO₂ over a decade by smoothing renewable generation. Such projects underscore the economic logic: as production of EV batteries accelerates, residual capacity after automotive retirement can offset the need for virgin cells in stationary or niche transport uses.
Research from McKinsey estimates that by 2030, more than 1.7 TWh of EV batteries will reach retirement globally. While most automakers emphasize recycling, repurposing is gaining traction because it delays energy-intensive material recovery and generates added revenue. SUSTAINera’s portfolio—encompassing reuse, remanufacture, repair, and recycling—aligns with this layered approach, but reliable testing protocols and clear liability rules will be essential to maintain customer trust and safety certification.
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