FOUNDATION IN HIGH VOLTAGE BATTERY ASSEMBLY OBJECTIVE

Module 1: Introduction to Battery Manufacturing Industry

This module introduces the battery industry, covering market growth driven by EVs and energy storage. Learners explore battery types, key applications, major manufacturers and supply chain stages, along with environmental challenges and opportunities.

Module 2: Health, Safety, and Environmental Regulations in Battery Manufacturing

This module prepares learners for safe practice in battery manufacturing. It covers key UK legislation (e.g. Health and Safety at Work Act, COSHH and DSEAR), PPE use, fire and electrical safety, risk assessments and emergency procedures. Environmental responsibilities, including waste management and pollution control, are also addressed.

Module 3: Overview of Battery Components and Materials

This module introduces key battery components, including anode, cathode, separator, electrolyte and current collectors, explaining their roles in energy generation. Learners explore common materials, cell formats such as cylindrical, prismatic and pouch, and their applications through classroom and workshop activities.

Module 4: Introduction to Electrode Manufacturing

This module introduces the key stages of electrode production, including mixing active materials, coating, drying, calendering, and slitting. Learners explore cleanroom environments, essential equipment and process flow through classroom, workshop, and immersive VR experiences.

Module 5: Cell Assembly Techniques

This module covers key cell assembly methods, including winding for cylindrical cells and stacking for prismatic and pouch cells. Learners explore separator placement, electrolyte filling and sealing techniques, with a focus on safety. Practical activities using coin cell equipment provide hands-on experience.

Module 6: Introduction to Formation, Ageing and Testing

This module introduces post-assembly processes, including initial cell charging (formation), stabilisation (ageing) and performance testing. Learners explore capacity checks, voltage and leak tests and safety evaluations to ensure cell quality and reliability.

Module 7: Module and Pack Assembly Processes (Classroom and Practical Activity)

This module covers how cells are connected into modules and packs, including wiring, cooling systems and enclosures. Learners explore high voltage safety, electrical isolation and hands-on assembly using industry components and smart tools, supported by classroom, VR, and workshop activities.

Module 8: Quality Assurance and Control in Battery Manufacturing

This module covers quality standards, testing procedures and documentation practices in battery manufacturing. Learners explore how to identify and manage non-conformances, ensure traceability and understand the importance of end-of-line testing and compliance with emerging regulations.

Module 9: Preventative Maintenance and Continuous Improvement

This module introduces routine maintenance practices to ensure equipment reliability, including checks, cleaning and fault reporting. Learners also explore continuous improvement methods like lean manufacturing, with hands-on group activities focused on efficiency and quality enhancement.

Module 10: Undertaking the Assessment (Classroom and Online Resources)

Learners receive guidance on building a portfolio of evidence and preparing for the multiple-choice test. Practical activities include logging tasks at workstations using card key access, with performance data recorded on the UCB LMS for tracking and achievement.