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Master'sElectromobility, Batteries & Hydrogen Applications open

Master’s in Battery Pack and Module Design

Online master's programme of 1,900 hours in battery pack and module design — mechanics, BOL/EOL, abuse and venting. 12 modules covering cells and pack requirements, module architecture, electrical interconnections, pack structure, integrated thermal management, pack electronics, safety, manufacturing, validation, sustainability and special applications, with an assigned technical tutor.

Duration12–14 months
ModeOnline
LanguageEnglish
Start datesSet by the faculty
AwardSEIUM Institute diploma
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Learning outcomes

What you will be able to do

01

Size packs according to vehicle requirements.

02

Design module and cell-to-pack architectures.

03

Design electrical interconnections and protections.

04

Design the mechanical structures and thermal systems of the pack.

05

Integrate the pack management electronics.

06

Ensure safety and validate the design.

07

Take manufacturing, sustainability and circularity into account.

Profile

Who it's for

  • Battery pack design engineers.
  • Module engineers.
  • Battery integration engineers.
  • Battery validation engineers.
  • Battery manufacturing engineers.
  • High-voltage engineers.
  • Engineering or science graduates looking to move into electric automotive.
Standards & tools

What you'll work with

  • UNECE Regulation No. 100 (electric powertrain safety)
  • ISO 6469-1 (on-board rechargeable energy storage safety)
  • IEC 62660-2 (reliability and abuse testing of lithium-ion cells)
  • Regulation (EU) 2023/1542 (EU Batteries Regulation)
  • UN 38.3 (lithium battery transport testing)
  • ISO 12405-4 (performance testing of lithium-ion packs and systems)
  • ISO 20653 (IP degrees of protection for road vehicles)
  • GB 38031 (Chinese EV traction battery safety requirements)
  • CATIA V5
  • Ansys Mechanical
  • MATLAB Simulink
  • Siemens NX
  • GT-SUITE
Syllabus

12 modules

  1. 1.1Energy and power requirements
  2. 1.2Chemistry selection
  3. 1.3Cell formats and their impact
  4. 1.4Series-parallel connection
  5. 1.5System voltage
  6. 1.6Pack specification
  7. 1.7Gravimetric and volumetric density
  8. 1.8Cost per kWh
  9. 1.9Benchmarks of commercial packs
  10. 1.10Case study: sizing a pack for an SUV
  1. 2.1The module concept
  2. 2.2Cell-to-module
  3. 2.3Cell-to-pack
  4. 2.4Cell-to-body and cell-to-chassis
  5. 2.5Retention structures
  6. 2.6Compression of pouch cells
  7. 2.7Cell swelling
  8. 2.8Cooling integration
  9. 2.9Comparison of architectures
  10. 2.10Practical: module architecture with prismatic cells
  1. 3.1Busbars and their design
  2. 3.2Laser welding of cells
  3. 3.3Ultrasonic welding
  4. 3.4Wire bonding
  5. 3.5Contact resistance
  6. 3.6Current distribution
  7. 3.7Fuses and protections
  8. 3.8High-voltage connectors
  9. 3.9Electrical insulation
  10. 3.10Lab: busbar and voltage drop calculation
  1. 4.1Housing and tray
  2. 4.2Materials: steel, aluminium and composites
  3. 4.3Stiffness and natural modes
  4. 4.4Impact and crush
  5. 4.5Underbody protection
  6. 4.6Vibration and fatigue
  7. 4.7Sealing and IP67
  8. 4.8Joints and adhesives
  9. 4.9Structural simulation
  10. 4.10Practical: modal analysis of a housing
  1. 5.1Pack thermal requirements
  2. 5.2Cold plates and their placement
  3. 5.3Thermal interfaces
  4. 5.4Coolant distribution
  5. 5.5Uniformity between modules
  6. 5.6Pack heating
  7. 5.7Propagation barriers
  8. 5.8Gas venting
  9. 5.9Temperature sensors
  10. 5.10Lab: design of the pack cooling circuit
  1. 6.1BMS architecture
  2. 6.2Cell monitoring boards
  3. 6.3Wireless BMS
  4. 6.4Junction box and contactors
  5. 6.5Pre-charge
  6. 6.6Current measurement
  7. 6.7Insulation monitoring
  8. 6.8Low-voltage wiring
  9. 6.9Communication with the vehicle
  10. 6.10Practical: high-voltage schematic of a pack
  1. 7.1Electrical safety
  2. 7.2Thermal safety
  3. 7.3Mechanical safety
  4. 7.4Hazard analysis
  5. 7.5Design FMEA
  6. 7.6Abuse testing
  7. 7.7UNECE Regulation 100
  8. 7.8GB 38031 and propagation
  9. 7.9Service disconnect
  10. 7.10Case study: FMEA of a module
  1. 8.1Module manufacturing processes
  2. 8.2Cell grading
  3. 8.3Stacking and compression
  4. 8.4Adhesive dispensing
  5. 8.5Line automation
  6. 8.6In-line quality control
  7. 8.7End-of-line testing
  8. 8.8Cell traceability
  9. 8.9Gigafactories and scale-up
  10. 8.10Lab: design of an assembly station
  1. 9.1Validation plan
  2. 9.2Electrical testing
  3. 9.3Thermal testing
  4. 9.4Mechanical testing
  5. 9.5Environmental testing
  6. 9.6Life testing
  7. 9.7Simulation-test correlation
  8. 9.8Non-conformity management
  9. 9.9Type approval
  10. 9.10Practical: DVP&R plan for a pack
  1. 10.1Design for disassembly
  2. 10.2Module repairability
  3. 10.3Second life
  4. 10.4Battery recycling
  5. 10.5Battery passport
  6. 10.6Carbon footprint
  7. 10.7Mandatory recycled content
  8. 10.8Regulation (EU) 2023/1542
  9. 10.9Raw material due diligence
  10. 10.10Case study: a pack designed for repair
  1. 11.1Packs for heavy vehicles
  2. 11.2Packs for motorcycles
  3. 11.3Packs for electric aviation
  4. 11.4Marine packs
  5. 11.5Stationary packs
  6. 11.6Swappable packs
  7. 11.7High-performance packs
  8. 11.8Requirements of each sector
  9. 11.9Technology trends
  10. 11.10Workshop: pack concept for a bus
  1. 12.1Pack requirements
  2. 12.2Cell selection
  3. 12.3Module architecture
  4. 12.4Electrical design
  5. 12.5Structural design
  6. 12.6Thermal design
  7. 12.7Safety and validation
  8. 12.8Cost and sustainability
  9. 12.9Master's Thesis report
  10. 12.10Master's Thesis: defence before a panel
Methodology, software & labs

How you'll learn

100% online learning on the SEIUM campus, with downloadable material, recorded classes and an assigned technical tutor. There are no fixed timetables: you progress at your own pace within the intake, so you can combine it with work.

Each module combines theory, guided reading of the original standard and applied exercises. The working software is CATIA V5, Ansys Mechanical, MATLAB Simulink, Siemens NX and GT-SUITE, in free, academic or evaluation versions. Testing is studied through real procedures: vibration and shock tests on packs, thermal tests in a climatic chamber, and sealing and insulation tests. Assessment is continuous by module, plus the final Master's Thesis.

Standards covered: UNECE Regulation No. 100, ISO 6469-1, IEC 62660-2, Regulation (EU) 2023/1542 (batteries), UN 38.3, ISO 12405-4, ISO 20653, GB 38031.

Assigned technical tutor:every module ends with a deliverable that your tutor marks individually.
Standards-based learning:guided reading of UNECE Regulation No. 100, ISO 6469-1 and IEC 62660-2 applied to real cases, not as a theoretical annex.
Industry software:CATIA V5, Ansys Mechanical, MATLAB Simulink, Siemens NX and GT-SUITE, in free, academic or evaluation versions.
Master's Thesis with defence:the complete design of a battery pack, from cell selection and module architecture to electrical, structural and thermal design, safety and cost, defended before a panel.
Flexible format:100% online, no fixed timetables, compatible with full-time work.
Capstone project

Build it end to end

Your final project follows the real engineering workflow, step by step, reviewed by your tutor.

Requirements and cell selection
Define the pack requirements and select the cell.
Module architecture
Design the module architecture and electrical interconnections.
Structural and thermal design
Design the pack structure and its integrated thermal system.
Safety and validation
Analyse pack safety and define the validation plan.
Master's Thesis
A complete pack design with cost and sustainability assessment, defended before a panel.
Career opportunities

Where this takes you

Battery pack design engineerModule engineerBattery integration engineerBattery validation engineerBattery manufacturing engineerHigh-voltage engineer
Admissions & scholarships

Requirements

  • University degree in engineering, science or architecture, or equivalent demonstrable professional experience.
  • Internet connection and a computer able to run the programme software.
  • English sufficient to read technical standards.

Ready to start?

Send your application today. Our admissions team replies within 72 hours with your study plan and funding options.

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FAQ

Frequently asked questions

The programme totals 1,900 hours over 12–14 months. You set your own pace within each intake, and your tutor helps you plan the workload around your job.

You work with CATIA V5, Ansys Mechanical, MATLAB Simulink, Siemens NX and GT-SUITE, using free, academic or evaluation versions. Your tutor indicates the free alternative wherever one exists.

A SEIUM Institute diploma, awarded on passing the continuous assessment and the Master's Thesis. It is SEIUM's own qualification, not an official state degree; its recognition depends on the programme completed and the regulations of each country.

Yes. Modules passed in a course or postgraduate diploma in the same area are recognised in the higher programme. Ask about the recognition policy when you enrol.

A degree in engineering, science or architecture (or equivalent professional experience), a computer able to run the software and English sufficient to read technical standards.

Start dates are set by SEIUM's faculty for each intake. Our admissions team will confirm the next available date when you apply.

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