Electric Vehicle Powertrain Boot Camp

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Course Overview: 

The EV Bootcamp teaches delegates how to design for manufacture, build and run production of the different primary elements of an electric vehicle’s (EV’s) powertrain. The EV industry is due to grow exponentially and it’s vital that those involved in automotive manufacturing, and its surrounding industries keep their technical knowledge up-to-date to remain at the forefront of the industry.

This Boot Camp is made up of the following modules:

  • Module 1 - The Fundamentals of Lithium-Ion Cells
  • Module 2 - Lithium-Ion Battery Pack Fundamentals
  • Module 3 - Electric Motor Manufacture
  • Module 4 - Electric Vehicle Manufacture
  • Module 5 - End of Life Pathways for EV Batteries

This programme is delivered in partnership with HSSMI.


Who should attend: 

This boot camp is intended for:

  • Engineers
  • Project Managers
  • Commercial staff looking to build on their technical understanding

Pre-requisites: 

No existing knowledge is required to undertake these courses.

Benefits and Learning Objectives: 

Module 1 - The Fundamentals of Lithium-Ion Cells

  • Understand what goes in to a lithium-ion cell and the key principles of electrochemistry
  • Describe how design and manufacturing decisions affect overall cell and battery pack performance.
  • Understand why cells fail and prevention methods 

Module 2 - Lithium-Ion Battery Pack Fundamentals

  • Specify battery packs to meet application requirements ensuring the correct cells are selected
  • Understand key principles and stages when manufacturing a battery pack
  • Understand the different levels of testing required in battery pack manufacture

Module 3 - Electric Motor Manufacture

  • Understand the inner workings of an electric motor, and how the choice of different materials and components affects its operation.     
  • Successfully design for manufacture, optimising processes, labour and machine choices to operate efficient, sustainable and high-speed manufacturing.

Module 4 - Electric Vehicle Manufacture

  • Understand the inner workings of an electric vehicle, and how the choice of different design strategies affects its operation
  • Successfully design for manufacture, optimising processes, labour and machine choices to operate efficient, sustainable and high-speed manufacturing

Module 5 - End of Life Pathways for EV Batteries

  • Describe why designing for end of life is important, and the different options for a product at the end of its first life
  • State the Legislation around the end of life for vehicles and batteries, its implications and future landscape
  • Define, describe, and evaluate the following end of life strategies, with practical examples: repair / reuse, refurbishment / reconditioning, battery remanufacturing, repurposing, recycling
  • Describe considerations that need to be taken into account when choosing a particular end of life strategy (e.g. volume, quality, state of health)
  • Make informed decisions about piloting or implementing end of life strategies for EV batteries

Topics Covered: 

Module 1 - The Fundamentals of Lithium-Ion Cells

  • Introduction to Electrochemistry 
  • Lithium-ion Cell Construction and Manufacture
  • Design for Performance and Cell Selection     
  • Safety, Failure Modes and Prevention

Module 2 - Lithium-Ion Battery Pack Fundamentals

  • Introduction to Electrical Fundamentals
  • Relating application requirements to battery design
  • Battery pack design principles
  • Battery pack design exercises
  • Production techniques with real case study
  • Production line testing

Module 3 - Electric Motor Manufacture

  • Brief history of the EM
  • DC vs AC motors
  • Motor construction (rotor, bearings, stator, air gap, windings, commutator)
  • Motor supply/motor control
  • Types of motor
  • Self-commutated motors and externally commutated motors
  • Special motor types
  • EMs advantages vs traditional ICE components
  • Today’s global EM market

Module 4 - Electric Vehicle Manufacture

  • Brief history of Electric Vehicle
  • Their types
  • Component parts
  • Associated manufacturing methods     
  • Life-cycle of EVs
  • High-level safety principles
  • Look at the current global EV market

Module 5 - End of Life Pathways for EV Batteries

  • Introduction to circular economy
  • Closed loop supply chains for batteries
  • Waste hierarchy for batteries
  • Extended producer responsibility legislation and its significance
  • End of life strategies for batteries
  • Evaluation of end of life strategies based on various considerations (e.g. state of health), in addition to case studies and examples
  • Tools for further decision-making and engagement with the topic (e.g. decision tree, EoL ForCE, CEMA)


Why choose SMMT QMD: 


In order to strengthen the services we provide to the UK’s automotive quality management specialists and further underpin the competitiveness of UK manufacturers, SMMT Industry Forum has created SMMT QMD, its new Quality Management Division.

SMMT QMD was launched at the inaugural Automotive Quality Management Systems Conference in Birmingham in November 2018 and aims to ensure that the UK automotive industry plays an active role in the development and governance of national and international automotive standards. 

SMMT QMD will provide a community of practice to directly support UK quality professionals, ensuring standards are effectively implemented and improving competitive performance. As such, SMMT QMD will now provide the following services:

  • An industry association for quality managers
  • Training, professional development and resources
  • Publications
  • Practical help and support
  • Course booking details:

Course Booking Details: 

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Further information

SMMT QMD is the Automotive Quality Management Division of SMMT Industry Forum.

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