Battery X Metals Inc. has announced a significant breakthrough in electric vehicle (EV) battery restoration through its wholly-owned subsidiary, Battery X Rebalancing Technologies Inc., which successfully increased the effective driving range of a light-duty electric truck from just 40 km to an estimated 265 km — a 563% improvement — using its second-generation, patent-pending “Prototype 2.0” diagnostic and rebalancing platform.
The milestone was achieved during a second real-world rebalancing procedure under a Commercial Revenue Share Agreement with an independent Vancouver-based auto service center specializing in out-of-warranty Tesla vehicles.
Rebalancing Restores Functionality & Detects Faulty Cell
The electric truck, a fully electric Class 3 commercial vehicle, was initially suffering from a critical voltage imbalance within its 144-cell NMC battery pack, rendering it inoperable below 60% state of charge (SOC). Prototype 2.0 successfully identified a Defective Cell within a parallel-connected group, which was subsequently replaced. This, combined with a proprietary rebalancing procedure, resulted in a 225 km increase in effective range compared to the pre-intervention range.
The restored range of 265 km closely aligns with the manufacturer’s claimed 290 km range under full load conditions, validating Battery X’s post-rebalancing performance data.
Breakthrough Diagnostic and Cell-Level Restoration
Prototype 2.0’s integrated diagnostic system enabled targeted detection of abnormal self-discharge in a defective cell and verified voltage disparities within the pack. After replacing the affected group with a matched cell set and performing a rebalancing operation, the vehicle showed dramatic improvements in range and performance — even under real-world mixed city and highway driving conditions.
Although a final balancing step was skipped due to time constraints, the post-procedure trial still showed that only 17% of battery capacity was used to cover 45.1 km, translating to a no-load driving range estimate of 265 km.
Commercialization and Broader Impact
The rebalancing platform’s effectiveness and scalability are being closely watched, especially as a growing number of EVs begin to fall out of warranty globally. According to industry estimates, nearly 40 million electric, plug-in hybrid, and hybrid vehicles are expected to exit warranty coverage by 2031, exposing owners to high costs of battery replacements.
Battery X Rebalancing Technologies aims to tackle this challenge by offering a cost-effective alternative to full battery replacements, extending EV battery life while contributing to environmental sustainability.
Prototype 2.0’s Market Potential Validated
The results reinforce the commercial viability of Prototype 2.0 in extending EV battery life and reducing total cost of ownership — key concerns in fleet and high-utilization environments. Previous validation by the National Research Council of Canada (NRC) confirmed that the technology could recover nearly all lost capacity due to cell imbalance in lab settings, and the current real-world success further validates its readiness for broader market deployment.
CEO Comments and Forward Plans
Battery X CEO Massimo Bellini Bressi highlighted the company’s vision to support the energy transition through a 360° battery metals strategy, combining exploration, recycling, and now lifespan extension technologies. “This trial demonstrates our ability to deliver real-world, high-impact results, and supports the expansion of our rebalancing platform into commercial settings,” he said.
As Battery X pursues a potential Nasdaq uplisting and U.S. market expansion, Prototype 2.0’s diagnostic capabilities and successful performance trials position the company as a front-runner in EV battery recovery innovation.
