Master’s in Battery Pack and Module Design Engineering
Online master's programme of 1,900 hours in battery pack and module design engineering. 12 modules covering pack requirements, electrical configuration, module design, thermal management, structural design, thermal propagation, sealing and environment, pack electronics and wiring, design for manufacture and service, and pack validation, with an assigned technical tutor.
Take the controls.
Run a real engineering trade-off from this programme. Move the sliders, watch the model react in real time and beat the challenge.
What you will be able to do
Define battery pack requirements from the vehicle.
Design modules and packs with cylindrical, prismatic and pouch cells.
Size the thermal management of modules and packs.
Design the pack structure to withstand loads and crashes.
Integrate measures against thermal propagation.
Design for manufacture, service and recycling.
Develop the complete design of a battery pack.
Who it's for
- Pack design engineers
- Battery mechanical engineers
- Battery thermal engineers
- Battery safety engineers
- Structural CAE engineers
- Pack industrialisation engineers
- Engineering or science graduates looking to join electric vehicle manufacturers
What you'll work with
- ISO 6469-1 (on-board rechargeable energy storage system safety)
- ISO 12405-4 (performance testing of lithium-ion traction packs and systems)
- UNECE Regulation No. 100 (safety of electric power trains)
- ISO 19453-6 (environmental conditions and testing for traction battery packs)
- GB 38031 (Chinese safety requirements for EV traction batteries)
- SAE J2464 (EV battery abuse testing)
- ISO 16750-3 (environmental conditions — mechanical loads)
- UL 2580 (batteries for use in electric vehicles)
- CATIA
- Simcenter STAR-CCM+
- ANSYS Mechanical
- LS-DYNA
- GT-SUITE
12 modules · 1900 h
1.1Energy and power1.2Nominal voltage and range1.3Available mass and volume1.4Vehicle integration1.5Pack thermal requirements1.6Safety requirements1.7Durability requirements1.8Target product cost1.9Regulations applicable to the pack1.10Case study: specification of a 75 kWh pack
2.1Cell selection2.2Series and parallel configuration2.3Module voltage2.4Module-less cell-to-pack architectures2.5Cell-to-body architectures in the chassis2.6Busbars and their sizing2.7Laser and ultrasonic welded joints2.8Contact resistance2.9Cell-level fusing2.10Practical exercise: electrical configuration of a pack
3.1Modules with cylindrical cells3.2Modules with prismatic cells3.3Modules with pouch cells3.4Cell compression3.5Swelling and its management3.6Supports and frames3.7Structural adhesives in modules3.8Sensors in the module3.9Module assembly3.10Workshop: CAD design of a prismatic module
4.1Heat generation4.2Cold plate design4.3Immersion cooling4.4Side and bottom cooling4.5Interface materials4.6Temperature uniformity4.7Battery heating4.8Thermal CFD simulation4.9System thermal tests4.10Lab: simulation of a cold plate
5.1Aluminium and steel housings5.2Composite housings5.3Stiffness and vibration5.4Underbody impact loads5.5Side impact requirements5.6Integration into the frame5.7Pack-to-vehicle fixings5.8Crash simulation5.9Mechanical tests of the assembly5.10Practical exercise: impact simulation with LS-DYNA
6.1Thermal runaway mechanisms6.2Thermal barriers between cells6.3Thermal insulation materials6.4Gas venting6.5Exhaust channels6.6Early thermal runaway detection6.7GB 38031 requirements6.8Propagation tests6.9Lessons-learned register6.10Case study: anti-propagation design
7.1Gaskets and sealing7.2IP protection ratings7.3Immersion tests7.4Pressure compensation valves7.5Condensation inside the pack7.6Corrosion and surface protection7.7ISO 16750-3 environmental tests7.8Vibration tests7.9Thermal shock tests7.10Lab: leak-tightness test
8.1Master and slave BMS8.2Sensing wiring8.3Temperature sensors8.4Battery disconnect unit8.5Contactors and pre-charge8.6Pack connectors8.7Wireless BMS communication8.8Grounding8.9Pack EMC8.10Workshop: sensing wiring design
9.1Assembly automation9.2Assembly tolerances9.3End-of-line tests9.4Product repairability9.5Module replacement9.6Safety during servicing9.7Design for disassembly9.8Pack recycling9.9Manufacturing costs9.10Practical exercise: DFMA analysis of a pack
10.1Validation plan10.2UNECE Regulation No. 100 tests10.3ISO 12405 tests10.4SAE J2464 tests10.5UL 2580 tests10.6Durability tests10.7Correlation between simulation and testing10.8In-vehicle validation10.9Failure management10.10Case study: DVP&R plan for a pack
11.1Integrated structural packs11.2Large-format cells11.3Solid-state packs11.4Sodium-ion packs11.5Modular packs for platforms11.6Packs for heavy vehicles11.7Packs for aviation11.8Cost optimisation11.9Battery pack sustainability11.10Workshop: structural pack concept
12.1Pack specification12.2Cell selection12.3Module design12.4System thermal design12.5Structural design of the assembly12.6Safety measures12.7Manufacturing plan12.8Validation plan12.9Master's Thesis report12.10Master's Thesis: defence before a panel
How you'll learn
100% online programme 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 each intake, so you can combine it with your job.
Each module combines theory, guided reading of the original standard and applied exercises. The working software is CATIA, Simcenter STAR-CCM+, ANSYS Mechanical, LS-DYNA and GT-SUITE, in free, academic or evaluation versions. Real procedures are studied: design of a 48-cell prismatic module with a cold plate, side impact simulation of an underfloor pack, and a thermal propagation test on a module. Assessment is continuous by module, plus the final Master's Thesis.
Standards covered: ISO 6469-1, ISO 12405-4, UNECE Regulation No. 100, ISO 19453-6, GB 38031, SAE J2464, ISO 16750-3, UL 2580.
Build it end to end
Your final project follows the real engineering workflow, step by step, reviewed by your tutor.
Where this takes you
Requirements
- University degree in engineering, science or architecture, or equivalent demonstrable professional experience.
- Internet connection and a computer able to run the programme's 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.
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, Simcenter STAR-CCM+, ANSYS Mechanical, LS-DYNA 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 university 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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