Redwood Materials Bolsters EV Battery Recycling with Tesla Veteran Mark Westfall

Redwood Materials, a leader in electric vehicle (EV) battery recycling, has welcomed Mark Westfall, a former Tesla engineer with a decade of experience, to its team. This strategic hire, announced on LinkedIn, strengthens Redwood’s mission to create a sustainable energy ecosystem by recycling and refining battery materials for new EVs, a process already supplying Tesla’s Gigafactory Nevada.

A Decade of Tesla Innovation

Westfall’s tenure at Tesla spanned critical advancements in EV infrastructure and energy storage. He contributed to three generations of Tesla Superchargers, facilitated the industry’s shift to the North American Charging Standard (NACS), and supported the launch of Powerwall 3 and grid-scale batteries.

“I’m truly proud of the work I’ve done over the years, launching three generations of Supercharger, transitioning the industry to NACS, ramping Powerwall 3, and helping develop the safest and most cutting edge grid scale batteries in the world,” Westfall shared on LinkedIn.

His expertise in mechanical design, reliability, and safety testing aligns with Redwood’s engineering-driven approach, making him a pivotal addition.

Redwood’s Recycling Revolution

Redwood Materials is transforming the EV supply chain by recycling batteries into high-quality materials like lithium and cobalt, reducing reliance on mining. In 2024, the company recycled 20 gigawatt-hours of batteries—nearly double Tesla’s Q4 energy storage deployment—demonstrating its scale.

This process produces up to 80% fewer emissions than traditional refining, shortening an EV’s environmental breakeven point to under 15,000 miles. “Redwood Materials’ recycling process produces up to 80% fewer emissions than traditional supply chain using CO2 belching refineries,” noted a Redwood Materials post on X.

Westfall’s role will focus on building a robust engineering team in San Francisco and Reno, enhancing Redwood’s capacity to meet growing demand.

Implications for EV Owners and Industry

For EV owners, Redwood’s advancements mean more sustainable vehicles with lower lifecycle emissions, potentially reducing costs as recycled materials stabilize supply chains. The company’s Nevada facility, which Westfall will help expand, processes batteries from consumer electronics and EVs, creating a closed-loop system.

Industry-wide, Redwood’s growth signals a shift toward circular economies, with competitors like Panasonic partnering on similar initiatives. Regulatory pressures for greener manufacturing further amplify Redwood’s relevance, as automakers face stricter emissions standards.

Building a Sustainable Future

Westfall’s move underscores Redwood’s appeal to top talent, driven by its “clarity of mission” and “first principles driven engineering culture,” as he noted. His recruitment push for engineers in mechanical design, reliability, and manufacturing test will accelerate Redwood’s expansion, including its new South Carolina plant. As EVs gain traction—projected to reach 30% of U.S. vehicle sales by 2030—Redwood’s recycling infrastructure, bolstered by experts like Westfall, positions it as a cornerstone of the sustainable energy transition.

Photos courtesy of Tesla.