Battery Comparison, Manufacturing, and Packaging Course

Lesson 1 • Key Performance Metrics

Defines energy density, power density, cycle life, and efficiency. Provides measurement vocabulary used throughout the course.

Lesson 2 • Battery Formats and Configurations

Introduces cylindrical, prismatic, and pouch cell formats. Connects physical form to application requirements and manufacturing constraints.

Lesson 3 • Electrochemical Principles of Batteries

Covers oxidation-reduction reactions, ion transport, and voltage generation. Establishes the chemical basis for all battery types discussed later.

Lesson 1 • Lead-Acid and Nickel-Based Chemistries

Reviews lead-acid, NiMH, and NiCd chemistries, including their strengths and limitations. Contextualizes legacy chemistries within modern battery markets.

Lesson 2 • Lithium-Ion Chemistry Variants

Compares NMC, LFP, NCA, and LCO cathode chemistries by energy, safety, and cost. Grounds chemistry selection in real application trade-offs.

Lesson 3 • Chemistry Selection Framework

Applies a structured decision matrix to match chemistry to application needs. Integrates performance, cost, safety, and lifecycle criteria.

Lesson 4 • Emerging Solid-State Chemistries

Examines solid electrolyte systems, lithium-sulfur, and sodium-ion technologies. Positions emerging chemistries relative to current commercial options.

Lesson 1 • Global Supply Chain Structure

Maps mining, refining, and cell manufacturing geographies. Highlights concentration risks and strategic dependencies in the battery supply chain.

Lesson 2 • Material Specification and Quality

Covers purity requirements, particle size, and moisture control for battery-grade materials. Links incoming material quality to finished cell performance.

Lesson 3 • Critical Mineral Identification

Identifies lithium, cobalt, nickel, manganese, and graphite as key battery inputs. Establishes material importance before exploring supply chain dynamics.

Lesson 1 • Slitting and Tab Welding

Covers precision slitting of electrode rolls and ultrasonic tab welding. Dimensional accuracy at this stage prevents assembly defects downstream.

Lesson 2 • Slurry Formulation and Mixing

Details active material, binder, conductive additive, and solvent ratios. Correct formulation directly determines electrode uniformity and capacity.

Lesson 3 • Electrode Defect Analysis

Identifies pinholes, agglomerates, delamination, and coating streaks as critical defects. Systematic root-cause analysis prevents yield loss in production.

Lesson 4 • Calendering and Densification

Explains roll-pressing to achieve target porosity and electrode density. Porosity control balances ion transport with energy density.

Lesson 1 • Electrolyte Formulation and Handling

Details lithium salt, solvent blends, and additive packages used in liquid electrolytes. Electrolyte composition governs rate capability and low-temperature performance.

Lesson 2 • Cell Housing and Sealing

Covers steel can crimping, aluminum prismatic casing, and pouch heat sealing. Hermetic sealing prevents electrolyte leakage and moisture ingress.

Lesson 3 • Dry Room and Cleanroom Requirements

Specifies dew point, particulate, and cleanliness standards for cell assembly environments. Environmental control directly impacts cell yield and long-term reliability.

Lesson 4 • Winding and Stacking Methods

Compares jelly-roll winding for cylindrical cells with Z-fold and flat stacking for prismatic and pouch formats. Format choice drives assembly line design.

Lesson 1 • Formation Cycling Protocols

Covers initial charge-discharge cycles that build the solid electrolyte interphase layer. Formation conditions set irreversible capacity loss and long-term stability.

Lesson 2 • Safety and Abuse Testing

Introduces nail penetration, crush, overcharge, and thermal runaway tests. Safety test results validate cell design against international performance standards.

Lesson 3 • Statistical Quality Control in Testing

Applies control charts, Cpk analysis, and sampling plans to production test data. Statistical methods distinguish process drift from random variation.

Lesson 4 • Aging and Self-Discharge Testing

Explains rest periods used to detect high self-discharge cells before shipment. Aging screens out latent defects that formation alone cannot reveal.

Lesson 1 • Pack Architecture and Configuration

Explains series, parallel, and series-parallel cell arrangements and their voltage and capacity effects. Configuration choice must match system voltage and energy requirements.

Lesson 2 • Thermal Management Design

Compares air cooling, liquid cooling, and phase-change thermal management approaches. Thermal design prevents hot spots that accelerate degradation and trigger failures.

Lesson 3 • Mechanical Structure and Busbar Design

Details cell holders, compression fixtures, and busbar sizing for current carrying. Mechanical integrity prevents vibration-induced failures in field applications.

Lesson 4 • Pack-Level Testing and Validation

Applies electrical, thermal, and mechanical tests to validate complete pack assemblies. Pack validation confirms that cell-level performance is preserved at system level.

Lesson 1 • Hazard Classification and Labeling

Explains dangerous goods classification, hazard pictograms, and UN number marking for batteries. Correct labeling is mandatory for legal transport and carrier acceptance.

Lesson 2 • Product Certification and Marking

Introduces safety certification marks, electromagnetic compatibility testing, and battery-specific performance standards. Certification marks are required for market access in most regions.

Lesson 3 • Packaging Material Selection

Covers cushioning, moisture barriers, and conductive foam for protecting battery products. Material choice must balance protection level with cost and sustainability goals.

Lesson 4 • Transport Regulations for Batteries

Covers air, sea, and ground transport rules for lithium and non-lithium battery shipments. Compliance prevents shipment rejection, fines, and safety incidents.