Week 1: EV Fundamentals & Architecture

Introduction to EVs: Classification (BEV, PHEV, HEV), industry standards (AIS/SAE), and sustainability goals.
Basics of EV Dynamics: Center of Gravity (CoG) shifts due to battery placement, regenerative braking physics, and rolling resistance.
CAD Fundamentals: Advanced surfacing for aerodynamics, modular part modeling, and master assembly management.
Technical Documentation: High-voltage safety labeling, wiring loom schematics, and Bill of Materials (BOM).


Week 2: Chassis & Powertrain Integration Skateboard

Chassis Design: Structural requirements for under-floor battery packs, material selection (aluminum vs. high-strength steel), and crashworthiness.
Electric Drivetrain: Motor types (PMSM vs. Induction), single-speed transmission vs. multi-speed, and gear ratio optimization for torque.
CAD Modeling: Designing motor mounts, gearbox housings, and axle interfaces.


Week 3: Battery Systems & Thermal Management

Energy Storage: Cell chemistry (LFP, NMC, Solid-state), cell-to-pack (CTP) architecture, and Battery Management System (BMS) logic.
Thermal Systems: Active liquid cooling vs. passive air cooling, heat sink design, and HVAC integration.
Power Electronics: Inverters, DC-DC converters, and onboard chargers (OBC) layout.
Analysis: Introduction to Computational Fluid Dynamics (CFD) for cooling ducts and battery airflow.


Week 4: Simulation & Validation
Structural & Dynamic Simulations: FEA for battery enclosures (IP67/69K standards) and suspension mounts under high-torque loads.
Performance Analysis: Simulating range (WLTP/NEDC cycles) and acceleration profiles.
Design Validation: Iterative design reviews based on simulation results and weight reduction (lightweighting) strategies.


Weeks 5 – 8: Final Project & Internship

Final Design Phase: Completing a full-vehicle design of an electric hatchback or urban commuter.
Optimization: Refining aerodynamics for drag coefficient reduction.

Presentation: Final design review with industry mentors, report preparation, and Professional Certification.