InCA (Inter Connected Cell Assembly)

A new battery cell design aims to cut weight, cost, and manufacturing complexity while making electric vehicle batteries faster to charge and easier to recycle. The project, called InCA (Inter Connected Cell Assembly), tackles a practical bottleneck in battery production: current cell designs are often optimised for one performance metric at the expense of others. Manufacturers must choose between lightweight cells, fast charging, or easy recyclability. InCA targets all three simultaneously by rethinking the internal structure of the cell and its connections to the wider battery pack. The goal is a flexible design that can adapt to future technological improvements without requiring a complete redesign. If successful, the impact would be felt along the entire UK battery supply chain. Lighter, cheaper cells with faster charging capability could lower the cost of electric vehicles and improve their usability. Simplified manufacturing processes should boost production reliability and quality, which matters for scaling up domestic battery factories. Increased use of recycled and sustainable materials in cell construction would reduce dependence on virgin raw materials and improve the environmental footprint of battery production. The project also strengthens UK expertise and market opportunities, supporting both domestic and European cell manufacturers.