Our research develops data-driven models to estimate batteries’ state of health. Moreover, the research optimizes the design of EV batteries for performance, lifespan, safety, power, and cost. We integrate battery modeling with supply chain consideration and lifecycle engineering concepts to design sustainable batteries. A combination of mathematical models, data science techniques, and lifecycle assessment methods are needed to identify the best design features for EV batteries for disassembly, repair, recycling, and reuse.