Done this myself. They don't replace the battery but send you a new AirPod or charging case.

My understanding is that opening an AirPod without damaging the plastic casing is close to impossible to do.

My guess would be they replace them then strip the components out of your returned AirPod or charging case and recycle/reuse what they can.

BOM looks like <$10 (there's barely anything inside). Maybe $15 with those small batteries. I doubt it's economical to recycle. What's fascinating is that people are willing to pay so much over the BOM. But I guess that's Apple speciality making people do it.

I think you're significantly underestimating the BOM on those.

> Wedbush analyst Dan Ives estimates that the cost of production of AirPods is $59–$69

https://articles2.marketrealist.com/2019/09/airpods-face-sti...

Hmm, I guess I've seen taerdown of something else than airpods on youtube, maybe a cheap clone and a mislabeled video. Heh.

Now I'm looking at iFixit teardown and it looks very different.

I guess you're right.

I'd bet they just give you a new one.