GM Rolls Out First EVs With Battery Cells Made From 100% Recycled Minerals
The closed-loop pilot recovered materials from 80 end-of-life GM batteries to produce over 12 metric tons of new cathode active material.
General Motors has begun delivering electric vehicles equipped with battery cells containing cathode active material made from 100% recycled nickel, cobalt, and manganese. The milestone marks the completion of a closed-loop recycling pilot designed to reintegrate recovered minerals into the company’s EV supply chain.
What Happened
The initiative involved recovering 80 end-of-life GM EV batteries, which were processed by partner Cirba Solutions into "black mass," a blend of battery materials derived from disassembled lithium-ion units. This black mass was converted into more than 12 metric tons of new cathode active material. Ultium Cells then manufactured new battery cells using this material, ensuring it met the same quality, safety, and performance standards as virgin materials. The resulting cells were assembled into packs at Factory ZERO and Spring Hill, powering the first batch of new Cadillac LYRIQ, LYRIQ-V, VISTIQ, ESCALADE IQ, and IQL models, as well as Chevrolet Silverado EV Trail Boss and GMC Sierra EV AT4 vehicles that have now rolled off the assembly line.
Why It Matters
Raw materials represent a significant portion of battery cell costs, so recovering and reusing them can support lower-cost batteries over time while reducing reliance on newly extracted minerals. GM states that current recycling technology can recover up to 95% of nickel, cobalt, and manganese, and up to 80% of lithium, depending on process conditions. This pilot provides a foundation for scaling circularity as more EV batteries reach the end of their useful lives in the coming decade. Additionally, GM is extending battery life beyond vehicles through second-life applications, such as deploying roughly 10,000 batteries for stationary energy storage in partnership with Redwood Materials.
The Bottom Line
GM’s closed-loop pilot successfully integrated recycled minerals into new EVs, validating a pathway for reducing supply chain dependence and potentially lowering costs. The company plans to share further details on these innovations at Climate Week NYC.
