- At this year’s Genera Exhibition 2025, LEITAT presented two of VERSAPRINT’s key technological developments:
- 3D-printed microchannel cooling technology (BB1)
- Easy-to-dismantle busbars for second-life and recycling (BB3 & BB4)
As a research centre driving several core innovations in the project, LEITAT showcased how advanced manufacturing and material engineering are enabling safer, lighter, and more sustainable battery systems for Europe’s next generation of mobility solutions.
3D-printed microchannels: enabling lighter and more efficient thermal management
One highlight at the booth was the silicon-based 3D-printed microchannel cooling system, developed within VERSAPRINT to drastically reduce weight while improving thermal performance.
Compared to traditional metal cooling plates, the microchannels:
- Reduce component weight by more than 25%
- Provide highly efficient heat extraction
- Help maintain optimal cell temperatures during fast charging
- Increase energy and power density at system level
Visitors at Genera received an in-depth explanation of how additive manufacturing allows complex internal geometries that cannot be produced through conventional techniques—unlocking new possibilities for multifunctional, high-performance battery components.
Next-generation busbars designed for circularity
LEITAT also presented the innovative busbars developed within VERSAPRINT, which are engineered for fast and cost-effective dismantling—an essential step toward circular battery systems.
These busbars offer:
- Manual disassembly in as little as 13 minutes (compared to more than 2 hours for standard designs)
- A reduction of disassembly cost from €3.99/kWh to €0.36/kWh
- Improved safety features integrated directly into the interconnection components
- Designs compatible with second-life use and enhanced recyclability
This work supports Europe’s ambition to create battery systems that are not only high-performing but also aligned with environmental and regulatory expectations.
A strong platform to connect with industry
Genera 2025 gathered leading stakeholders from energy, renewables, engineering, and sustainability. LEITAT’s presence allowed the VERSAPRINT project to:
- Engage with industrial partners interested in advanced thermal management and circular design
- Showcase the project’s modular Building Blocks approach
- Strengthen connections with companies seeking innovative battery technologies for mobility and stationary applications
- Highlight how EU-funded research translates into practical, scalable solutions
LEITAT’s participation at Genera demonstrates the value of interdisciplinary collaboration within VERSAPRINT: combining additive manufacturing, materials science, eco-design, and system engineering to deliver adaptable, safe, and sustainable battery systems.
As VERSAPRINT enters its next phase of validation and testing, these results mark an important step toward multifunctional, industry-ready battery technologies that can support Europe’s mobility transition.
Stay tuned for more updates from our partners across Europe.