FLUENTLY PROJECT

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MEM and the Fluently Project
A Vision for Electric Mobility in Malta

MEM is proud to be part of the Horizon Europe project Fluently, which brings together a diverse consortium to shape the future of local, sustainable vehicle manufacturing across Europe. As part of this initiative, MEM has developed a comprehensive study and a compelling vision for a microfactory dedicated to producing electric vehicles (EVs) in Malta.

The video on this page showcases MEM’s concept: a low-investment, fully integrated production facility capable of manufacturing a wide range of electric vehicles tailored to the island’s needs. This includes urban electric cars, delivery vans, e-bikes, and cargo bikes, covering 2-, 3-, and 4-wheel configurations. The vehicles are designed with high-strength tubular steel frames, combining durability, safety, and cost-efficiency.

This microfactory model aligns with Malta's strategy to promote green, locally-made solutions and reduce reliance on imported vehicles. It demonstrates how small-scale, flexible production lines can support sustainable mobility, job creation, and industrial innovation on the island.

To support the development of this vision, MEM has applied for a specific grant to Malta Enterprise, reinforcing its commitment to establishing a pioneering hub for clean transportation technologies in Malta.

Learn more about the Fluently project at fluently-horizonproject.eu

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FLUENTLY Training Initiative for Robotized Manufacturing of E-Bikes

Through the Fluently initiative, MEM is dedicated to the strategic enhancement of human capital within Malta’s manufacturing sector. MEM has carefully studied and designed a specialized "Robotics and Industry 4.0" training laboratory to deliver targeted training in industrial robotics, with an initial focus on preparing individuals for roles specifically related to the robotic manufacturing of electric bikes (e-bikes).

The primary mission of the Fluently initiative is to establish a robust collaboration between Maltese educational institutions and local industry partners. This partnership ensures that trainees acquire the exact skills and competencies required for successful careers in Malta’s rapidly expanding electromobility sector.

Targeting graduates from Industrial Technical Institutes, the laboratory provides focused training to cultivate two distinct professional roles:

  • Programmer 4.0
  • Maintenance Technician 4.0

Training is centered around a "learning by doing" methodology, offering students practical, hands-on experience that closely mirrors real workplace scenarios. This approach effectively builds both technical abilities and crucial soft skills such as problem-solving, teamwork, and public speaking.

Beyond the immediate objective of equipping trainees with the skills needed for robotic e-bike manufacturing, the Fluently initiative seeks to bridge the gap between academic education and practical industry requirements. Through structured internships, specialized training modules, and industry-oriented events, MEM actively contributes to Malta’s socio-economic development. This approach positions human capital investment as a pivotal driver of local competitiveness and innovation.

To ensure the professional and effective implementation of the laboratory concept, MEM has formalized an agreement with COMAU, a global leader in advanced systems and products for industrial automation.

Specific Proposal for MEM Robotics and Industry 4.0 Training Laboratory for e-bike and battery packs production and reconditioning

Advancements in artificial intelligence and robotics are transforming manufacturing industries, offering significant opportunities for professional growth at all levels. As job roles rapidly evolve, there is a growing demand for new competencies, particularly among product designers, industrial automation system technicians, production operators, and maintenance technicians.

Responding to this transformation, MEM proposes establishing a dedicated Robotics and Industry 4.0 Training Laboratory. This facility will replicate an authentic production environment, equipped with advanced robotic systems, to deliver practical, industry-relevant training.

Purpose:

The proposed laboratory aims to:

  • Equip students and trainees for immediate employment in MEM’s e-bike manufacturing operations.
  • Facilitate meaningful collaboration between Maltese educational institutions and local manufacturing companies.
  • Enable local businesses to upgrade employee skills in robotics without substantial capital investment.
  • Foster practical and experiential learning, enhancing technical skills alongside soft skills like communication, teamwork, and problem-solving.

Training Modules:

The laboratory will provide comprehensive modules:

  1. Industry 4.0 and Sustainable Production Management (40 hours)
  2. Digital Enabling Technologies (40 hours)
  3. Business and Product Innovation (40 hours)
  4. COMAU e.DO Robot Programming and Operation (40 hours)
  5. eBike Assembly Learning Factory (40 hours)
  6. Virtual Learning Factory (40 hours)

Each module balances theoretical learning with extensive practical experience, enabling trainees to apply their knowledge directly to real-world manufacturing processes.

Laboratory Layout and Equipment:

The laboratory setup will closely resemble an actual industrial manufacturing site and will include:

  • COMAU e.DO robotic systems and automation equipment
  • Specialized workstations for assembly and maintenance
  • Comprehensive IT infrastructure, including laptops, tablets, and relevant simulation and programming software

By closing the gap between education and industry requirements, the proposed MEM Robotics and Industry 4.0 Training Laboratory will significantly advance human capital development in Malta, effectively supporting the growth and innovation of the local electromobility sector and contributing broadly to economic development objectives.

The presentation detailing the Robotic laboratory concept
for the manufacturing of e-bikes is shown in the following slides

Human-Robot Collaboration for Sustainable e-bike Battery Lifecycle: The MEM Use Case

Introduction: A Shared Vision for Sustainable Manufacturing

In the context of the FLUENTLY project, Malta Electromobility Manufacturing (MEM) took on the challenge of transforming one of the most pressing issues in modern e-mobility: how to assemble, recondition, and dismantle e-bike battery packs safely, sustainably, and at scale. This use case exemplifies the potential of AI-driven, human-centric automation, brought to life through MEM’s tight collaboration with the robotic lab at SUPSI and the broader FLUENTLY consortium.

Batteries are at the heart of the electric mobility revolution, but they pose challenges when it comes to durability, safe handling, and recycling. MEM’s pilot was designed to showcase how the FLUENTLY platform, a novel human-robot interface based on speech, gesture recognition, and context awareness, could enhance each stage of the battery lifecycle, all while empowering human operators.

Reconditioning, Disassembly and Recycling: A Complex Workflow Reimagined

The MEM pilot focused on the reconditioning and disassembly of used e-bike battery packs. The project aimed to:

  • Minimize reliance on skilled experts,
  • Enable safe, efficient recovery of battery cells,
  • Align with EU Regulation 2023/1542, which mandates the design of transport batteries for easy dismantling.

To evaluate impact, MEM used FLUENTLY’s standardized KPIs. The highlights:

KPI Title Results Impact
1 Programming Effort >50% reduction in setup time Enabled non-experts to manage robotic tasks
4 Human Awareness Real-time posture & fatigue detection Safer handling of unstable components
5 Self-Awareness Robots adjusted behavior by load Prevented equipment overload
6 Robot Empathy Speed/path adapted to operator fatigue Higher safety, trust, and acceptance
7 Recipe Acceptance Robot workflows created from demonstrations Adapted to varied battery designs
8 Knowledge Availability Onboarding in < 5 days Upskilled operators without robotics background
12 Process Efficiency Index 75%+ cell recovery, 60% error reduction Surpassed circular economy targets

Qualitative feedback from operators highlighted intuitive interfaces, multilingual support, and increased confidence due to fatigue-aware robotic behavior. The pilot confirmed that even operators without robotics experience could become autonomous within days, a leap forward in workforce scalability.

Addressing the Challenges of Battery Reuse

The disassembly of battery packs is a delicate task, made more complex by:

  • Heterogeneous pack structures and non-standardized materials,
  • The fragility of internal layers, limiting full automation,
  • A lack of existing structured workflows for safe disassembly.

The FLUENTLY platform helped MEM overcome these challenges by:

  • Integrating AI vision systems to detect battery structure,
  • Automating outer casing and cell-level handling,
  • Empowering workers through operator-in-the-loop support, with real-time contextual feedback from FLUENTLY.

This approach ensures not just automation, but safe collaboration — where robots intelligently share the workload, and humans remain in control.

Full Battery Lifecycle Support: From Assembly to Reconditioning

Beyond disassembly, MEM demonstrated how FLUENTLY can enhance the entire battery lifecycle, including:

  • Assembly: Robots interpret gestures and commands for safe, precise pack construction.
  • Testing: Real-time AI-assisted QC reduces errors and process downtime.
  • Reconditioning: Robots identify and replace faulty cells without full pack replacement.
  • Recycling: Collaborative robotics disassemble components safely, now required under EU regulation.

This integrated approach meets the demand for flexible, human-centric automation, while also supporting the circular economy and sustainability goals of the EU Green Deal.

A Vision for the Future: Scaling MEM’s Innovation

Looking ahead, MEM plans to scale and industrialize the results of this pilot by:

  • Launching a certified AI training center for battery reconditioning and robotic disassembly.
  • Expanding cooperation with SUPSI and other EU research labs for next-gen methods.
  • Enhancing robot dexterity using digital twins to adapt to battery conditions in real time.
  • Commercializing a semi-automated disassembly line tailored for light electric vehicle batteries.

Through this roadmap, MEM not only ensures compliance with new regulations, it becomes a reference model for sustainability and innovation in the e-mobility sector.

Pilot Video

To see the MEM use case in action — including human-robot collaboration for battery pack disassembly, reconditioning, and recycling watch the video below.