EV Li-ion Battery Manufacturing Techno Commercial Course

Lithium-Ion Battery Pack Assembly: Course Syllabus

Learn the Lithium Technology. Build the Business.
Online techno-commercial training in lithium-ion battery pack design, assembly and costing, with hands-on simulation.

Who it’s for: Entrepreneurs, startups and working professionals who want to design, assemble and run a lithium-ion battery pack business for EV and energy storage.

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Part A: Foundations

1. EV Market and Business Opportunities
Li-ion market, raw materials and India’s position, government policy and incentives, EV market trends.
Outcome: Spot growth segments and understand the policy landscape.

2. Types of Lithium-ion Batteries
Battery types and chemistries (LCO, LMO, NMC, LFP, LMFP, LTO), lithium vs sodium-ion, cell formats, C-rate, basic safety tests.
Outcome: Compare chemistries and pick one for an application.

3. Cell Parameters
Voltage, capacity, internal resistance, OCV and SOC, SOH, cycle life, CCCV charging, fast vs slow charging, heat and degradation.
Entering a cell datasheet in the simulator and building a cell model (OCV curve, resistance, time constants).
Outcome: Read a datasheet and evaluate a cell.

4. Cell Chemistry
Cathode, anode, electrolyte, separator, SEI, lithium plating and dendrites, recycling.
How ageing mechanisms (SEI growth, plating) affect predicted pack life.
Outcome: Link chemistry to performance, safety and life.

5. Cell Architecture
Cylindrical, pouch, prismatic cells, internal parts, vents, CID and PTC safety devices, India’s manufacturing growth.
Outcome: Understand how cell construction affects safety and design.

Part B: Pack Systems

6. Battery Management System (BMS)
Protection, balancing, monitoring, communication, centralized vs distributed BMS, PCB vs BMS, series-parallel connections.
Cell-to-BMS compatibility check, protection and balancing simulation, SOC estimation, fault-injection testing, intro to generated BMS code with SIL/HIL.
Home task: BMS datasheet analysis, plus a compatibility check in the simulator.

7. Battery Thermal Management (BTMS)
Heat generation, air, liquid and refrigerant cooling, phase change materials, thermal runaway.
3-D cooling simulation (air, liquid cold plate), design targets (Tmax ≤ 45 °C, cell-to-cell ΔT ≤ 5 K), thermal imaging view.
Outcome: Select and compare cooling approaches.

8. Battery Testing and Compliance
Capacity, OCV and IR tests, BMS test, thermal cycling, overcharge test, BIS certification, IATA lithium battery regulations, battery health testing.
Thermal runaway and propagation simulation with barriers, safety and compliance checklists (AIS-156, AIS-038, IS 16893, UN R100, UN 38.3, IEC 62619), and knowing which results need real tests.
Outcome: Run key tests and understand certification routes.

Part C: Design and Simulation

9. Battery Module and Pack Design
Pack design steps: application, chemistry, series-parallel layout, BMS, thermal system, enclosure, specification, OEM case studies, customisation.
Sizing a pack in the simulator and reading its PASS / WARN / FAIL checks, plus fuse, busbar and pre-charge sizing.
Home task: Pack design and SORT analysis document, plus a saved simulator project.

9A. Pack Design Simulation Lab 
Hands-on use of the IST Li-ion Battery Simulator software, following its 12-step workflow from application targets to a design report. Class example: a 48 V, 150 Ah LFP three-wheeler pack.
Lab exercises: re-size for a different cell, compare cooling methods, choose the lightest safe barrier, compare ageing in two climates.
Outcome: Take a pack from targets to a documented design, and state what still needs physical validation.

Part D: Business

10. Assembly Line and Financial Projection
Production and quality metrics, assembly equipment, factory layout, costing, working capital, ROI, revenue streams.
Outcome: Build a financial plan for an assembly line.

11. Business Guide and Final Project
Company, GST and MSME registration, trademark, branding, marketing, product certification, supplier and OEM networking, post-training support.
Final project includes the simulator design report and bill of quantities.
Outcome: Present a complete project and know the steps to start the business.

Support and Assessment

• Method: Live classes with whiteboard calculations, case studies, recorded sessions on the e-library, doubt sessions.
• Materials: 78 books, class notes, datasheets and Excel files, plus the simulator User Guide.
• Practical: Optional hands-on lab at the institute, and simulator exercises online.
• Assessment: Home tasks, project submission and online exam, leading to an e-certificate and e-marksheet.
• Languages: English, Hindi and Bengali.

Academy of EV Technology (AEVT) : Program code SLBPA | Online live classes | 2 months technical classes + 1 month self project work | Starts November 2026 | Entry: 12th pass, age 18+

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About IST Li-ion Battery Simulator (V-10.0.1)

A browser-based workbench for designing lithium-ion battery modules and packs, with nothing to install. It is aimed at battery assembly companies, EV and energy storage integrators, and engineering students.

What it covers:

• Pack sizing: voltage, energy, resistance, current limits, mass and volume, with pass/warn/fail checks against your targets
• Cell modelling: equivalent-circuit and electrochemical models
• Thermal analysis: cooling simulation (air, liquid, natural convection), thermal runaway and propagation with barrier comparison
• BMS design: protection, balancing, SOC/SOH estimation, drive-cycle simulation (MIDC, WLTC and others), and C code generation with SIL/HIL testing
• Circuit design: fuse, busbar and pre-charge sizing, module wiring diagrams
• Safety and compliance: electrical and abuse checks, with a standards checklist (AIS-156, AIS-038, UN R100, UN 38.3, IEC 62619)
• Life prediction: calendar and cycle ageing, warranty claim estimates
• Reports: a one-click A4 design report with a bill of quantities, saved as a .pro project