Sustainable Battery Design

Understand the battery module and pack materials selection

Chemistry selection based on energy efficiency and sustainability criteria. Consider cathode chemistries: LFP - Cobalt-free, lower carbon footprint. High-Ni NMC: higher energy but relies on critical metals (Ni, Co). Anode innovations based on Silicon-graphite blends with higher capacity, but swelling challenges. Design challenges with recycled graphite. Recycled Aluminium/steel for casing vs. polymers. Designing with non-toxic dielectric cooling fluids.

Understand the specifics of battery design process

Apply correctly the knowledge of the battery manufacturing specifics (from electrode, to cell, to module, to pack) in each stage of the design (concept, design, validation, prototype, testing).

Know and understand the module and pack design strategies

Considering cell-to-pack vs. modular systems and its impact on repair, recycling cost vs. energy density and ease of manufacturing. Be able to optimise design related to overal cost, weight, performance and lifetime.

Apply knowledge from power electronics and automatic control systems in BMS design

BMS hardware design and optimisation for maximum safety and performance. BMS software development including algorithms for SoC/SoH estimation and balancing strategies. Integration with pack design for optimal thermal management and reuse/recycle readiness.

Utilise engineering software and tools

Familiarity with standard CAD SW (CATIA, SolidWorks), thermal and structural simulation (ANSYS, COMSOL), electro-chemical performance modelling (GT-AutoLion, MATLAB), LCA (SimaPro/GaBi), and specialised battery diagnostics SW packages.

Understand sustainability in relation to battery module and pack design and manufacture

Design for Recycling (DfR): ease of disassembly (snap-fit vs. welded joints). Second-Life Optimization: state-of-Health (SoH) thresholds for repurposing (e.g., 70–80% residual capacity). Modular architecture (replaceable cell groups).

Understand the main components and organisation of a battery module and pack

Identification of battery module and battery pack components on engineering drawings or CAD images, components (including the identification of components which are incorrectly located).

The broad purpose of the occupation is to be able to plan and lead projects or other relevant programmes of work that provides critical analysis, continuous improvement and problem solving to support research, design and development activities. As part of the development of new products and technology, designers and engineers have to analyse requirements and consider any legal implications and limitations to ensure conformity to national or international legislation, standards or directives as well as complying with customer requirements. It is imperative that material properties, capabilities and failures are understood and recognised to allow appropriate material selection. Product design and development engineers use a range of computer packages in order to complete the design or development activity efficiently and effectively including presenting their conceptual ideas. They utilise cutting edge technology to realise a project from initial concept studies to integrated analysis of a complete system. This is made possible with the introduction of advanced Computer Aided Design (CAD) and Computer Aided Engineering (CAE) software packages and the availability of Computer Aided Manufacturing (CAM) software packages to support the design and development process.

Developed with industry partners, this apprenticeship programme ensures organisation has the skills and expertise needed to drive critical engineering innovation in electrification. It also supports upskilling.

Fourth year specialism on batteries include: fundamental chemical and electrochemical principles for batteries, battery materials and characterisation, battery manufacturing, testing and sustainability, battery management systems.

Battery Technologies and their Applications Module - Having successfully completed this module you will be able to: explain the underlying principles of the different battery chemistries, apply knowledge of key performance parameters to select an appropriate battery chemistry for a target application, analyse the key parameters used to characterise battery technologies