The potential of lower greenhouse gas emissions makes the transition from internal combustion engine vehicles (ICEV) to electric vehicles (EV). The transition is essential due to the growing concerns regarding climate change. But this urgent transition raises huge concerns about the sustainability of the life cycle of battery pack and its capacity to be recycled. Traditional electric vehicle battery modules widely use adhesive glues to hold the battery cells inside the battery module. These adhesive glues have a significant challenge regarding material recovery and end-of-life treatment and disassembly. This thesis presents an unconventional design alternative by developing a mechanical clip mechanism to replace the adhesive glues inside the battery module. The study tries to match the battery design with the conventional concepts of circular economy, increasing the material recovering efficiency and improving the recyclability of the battery pack. The study mainly evaluates the performance of three different types of materials for the clip: titanium alloy (Ti6Al4V), aluminum alloy (7075-T6) and low carbon high strength steel (AISI 1005). The comparison is done through material analysis, design calculations, and cost analysis. The ideal clip thickness and the mechanical stability under the operation conditions are evaluated using the beam bending theory. The study also utilizes the lifecycle assessment (LCA) to evaluate the energy content and environmental footprints of the lithium-ion battery modules, which highlights the necessity of a new and innovative sustainable design. The study reveals that using a mechanical clip improves the ability of the electric vehicle battery to be disassembled, boosting the recovery rates of valuable materials like lithium and cobalt. But some trade-offs have to be made, which is the cost of production. This study is carried out under the framework of work integrated learning (WIL), combining theory and industrial practice.