ARTI continues to prepare recyclers for high-voltage vehicles. In collaboration with Argonne National Laboratory.
By Zach Schauls
The goal is clear: to equip automotive recyclers with the knowledge and skills necessary to process high-voltage vehicles safely and efficiently, while also preparing them for future developments that will continue to reshape the industry.
By embracing these opportunities, the auto recycling industry can play a key role in the circular economy.
“I don’t recycle electric vehicles.”
It’s a phrase still heard across the industry, but it no longer reflects reality. The truth is that many recyclers are already handling high-voltage vehicles, whether they realize it or not. A 10-year-old hybrid SUV may look no different from a conventional internal combustion engine vehicle on the outside, yet under the hood, or more often, beneath the floor, there may be a high-voltage system capable of causing serious harm if not properly identified and managed. The misconception that high-voltage vehicles are rare, obvious, or easy to avoid is precisely why updated training has become so critical.
The rapid evolution of the automotive industry over the past two decades has fundamentally reshaped not only how vehicles are designed and manufactured, but also how they must be handled at the end of their life cycle. Nowhere is this transformation more evident than in the rise of high-voltage vehicles (HVVs), including hybrid electric vehicles (HEVs), plug-in hybrids (PHEVs), and fully electric vehicles (EVs). As these technologies have advanced, so too have the complexities and risks associated with dismantling and recycling them.
In response, the Automotive Recyclers Training Institute (ARTI) has undertaken an ongoing project to revise high-voltage vehicle training—an effort that represents a critical step toward ensuring the auto recycling industry remains safe, effective, and aligned with modern technological realities.
From the earliest days of hybrid vehicle adoption, the organization recognized that high-voltage systems would introduce new challenges that traditional dismantling practices were not equipped to handle. This foresight led to the development of one of the industry’s first comprehensive guides focused specifically on high-voltage vehicle safety and dismantling procedures.
The original training materials developed by ARA were built around early hybrid models, which at the time represented the cutting edge of automotive electrification. These vehicles introduced entirely new concepts to many in the recycling sector: high-voltage battery packs, electric drive motors, and complex power electronics. While those early hybrids were relatively simple compared to today’s vehicles, they marked a turning point. They required technicians to rethink how they approached vehicle systems—especially when it came to electrical hazards, stored energy, and safe deactivation procedures.
As the automotive industry accelerated toward electrification, however, the limitations of those early training materials became increasingly clear. Modern electric vehicles are far more sophisticated than their predecessors. They operate at significantly higher voltages, utilize larger, more energy-dense battery packs, and incorporate advanced thermal management systems. In addition, integrated software now plays a major role in controlling safety mechanisms and system behavior, adding another layer of complexity for recyclers.
Unlike traditional internal combustion engine vehicles, which are primarily mechanical, high-voltage vehicles are deeply rooted in electrical and electronic systems. This shift introduces a range of new risks, including electric shock, arc flash (essentially an electrical explosion), fire hazards, and chemical exposure from damaged battery components. These are not theoretical risks; they are real, and they require a new level of awareness and preparation.
Vehicle design itself has also evolved in ways that directly impact dismantling. Many EV battery packs are mounted along the bottom of the vehicle, often forming part of the structural platform. This means that improper lifting—such as using forks or contact points in the wrong location—can damage the battery pack. That damage may not be immediately visible, but it can lead to delayed thermal events, including fires that occur hours or even days after the initial incident. For recyclers accustomed to lifting vehicles from traditional frame points, this represents a significant change in procedure and mindset.
Recognizing these challenges, ARTI has taken proactive steps to revise its high-voltage vehicle training program. The goal is clear: to equip automotive recyclers with the knowledge and skills necessary to process high-voltage vehicles safely and efficiently, while also preparing them for future developments that will continue to reshape the industry.
One of the most important advancements in this revised program is the transition from static written guides to a more dynamic, multimedia learning experience. Through ARA University, the organization has developed a training platform that delivers content in a virtual classroom environment. This approach allows learners to engage more deeply with the material, combining visual instruction with practical demonstrations.
Visual learning is especially valuable when dealing with high-risk procedures. It reinforces critical safety concepts and helps ensure that technicians understand not only what to do but also how to do it correctly. In a field where mistakes can have serious consequences, this level of clarity is essential.
Beyond technical procedures, the training also emphasizes situational awareness and decision-making. No two vehicles are exactly alike, and even within the same model, variations in condition, damage, or prior modifications can introduce new risks.
Technicians are encouraged to assess each vehicle individually, identify potential hazards, and adapt their approach accordingly. This mindset—thinking before acting—is one of the most important safety tools available.
A key strength of ARTI’s training initiative is its commitment to collaboration. By partnering with leading research institutions such as Argonne National Laboratory, ARTI has incorporated cutting-edge scientific knowledge into its materials. Argonne brings deep expertise in battery technology, energy systems, and advanced materials—areas that are directly relevant to the challenges recyclers face every day.
This collaboration ensures that the training program is not just reactive, but forward-looking. As battery technologies continue to evolve—moving toward solid-state designs, new chemistries, and higher energy densities, the risks and handling requirements will also change. By integrating insights from Argonne, ARTI is helping to prepare recyclers for what’s next, not just what exists today.
The pace of technological change in the automotive sector is unprecedented, and no single organization can keep up on its own. Collaboration between industry groups, researchers, and recyclers themselves is essential for developing effective, standardized approaches.
This shared effort helps reduce variability across the industry and improves overall safety outcomes.
It also addresses an important, often-overlooked reality: high-voltage systems are no longer limited to fully electric vehicles. Many modern internal combustion vehicles—including trucks and SUVs—now incorporate hybrid systems or high voltage components that may not be immediately obvious. These “hidden” systems can catch recyclers off guard if proper identification procedures are not followed. Updated training ensures that workers know what to look for, even when high voltage presence is not clearly marked.
Safety remains the central focus of the training program, and for good reason. High-voltage systems store significant amounts of energy, even when a vehicle is powered down. Improper handling can result in electric shock, arc flash, or thermal runaway events. Understanding how to properly isolate and manage that energy is critical to preventing injuries and incidents.
At the same time, the training emphasizes that safety is not just about individual knowledge; it is also about communication and teamwork. Dismantling high-voltage vehicles often requires multiple people, each with a specific role. Clear communication ensures that everyone understands the vehicle’s status, the steps being taken, and any hazards identified. A strong safety culture encourages workers to speak up, ask questions, and stop work if something doesn’t seem right.
Looking ahead, the continued evolution of vehicle technology will bring new challenges.
Autonomous systems, advanced sensors, and increased connectivity will further complicate vehicle design and dismantling processes. These developments will require ongoing updates to training programs and continued collaboration across the industry.
ARTI’s proactive approach reflects a clear understanding of these challenges. By continuously updating its training and working with partners at the forefront of research, the organization is helping to ensure that recyclers are not left behind as the industry evolves. This is not just about keeping up—it’s about leading the way.
Another major factor driving the need for updated training is the changing landscape of vehicle production. Many automakers have already committed to transitioning toward fully electric lineups within the next decade. As a result, the number of high-voltage vehicles entering the end-of-life stream will continue to grow.
For recyclers, this means that handling high-voltage systems will soon become a core part of daily operations rather than a specialized task. It also presents new opportunities. Electric drivetrains and battery systems contain valuable materials, including rare-earth elements used in motor magnets, such as neodymium, cobalt, and nickel. Recovering these materials not only provides economic value but also supports the broader supply chain for future technologies.
By embracing these opportunities, the auto recycling industry can play a key role in the circular economy. Recovering and reusing materials reduces the need for new resource extraction, lowers environmental impact, and supports the sustainable growth of electric mobility. But none of this is possible without the knowledge and training needed to do the work safely.
Ultimately, the project to revise high voltage vehicle training represents a vital investment in the future of auto recycling. It acknowledges the reality that high voltage systems are already present across a wide range of vehicles—often in ways that are not immediately visible—and provides the tools needed to address that reality.
“I don’t recycle electric vehicles” is no longer a safe assumption. The better approach is to assume the opposite: that any vehicle could contain high voltage components, and to be prepared accordingly.
Through updated training, innovative learning methods, and strong industry partnerships, ARTI is helping recyclers make that shift. In doing so, it not only improves safety but also positions the industry to thrive in a rapidly changing automotive landscape.
Zach Schauls graduated from Iowa State University, with a degree in mechanical engineering and a specialty in electric vehicle systems and sustainability for recycling. This passion began from dismantling hybrid transmissions, gaining hands-on experience with electric drivetrains and component recovery and sparked his interest in end-of-life vehicle processing and materials reuse, specifically for electric vehicles. Zach also conducts environmental and safety audits to help organizations improve compliance and reduce operational risks. His technical expertise brings a practical perspective to scaling electric vehicle recycling and advancing efficient, sustainable solutions in the evolving automotive industry.
