Cell electro-mechanical testing: A key skill revolutionising UK Battery Testing

The UK's transition to electrification is accelerating, driven by climate goals and technological advancements. Central to this shift is cell electro-mechanical testing, a critical process ensuring the safety, efficiency, and reliability of battery systems powering electric vehicles (EVs) and renewable energy solutions. As the UK positions itself as a global leader in battery technology, addressing the skills gap in this specialised field has become urgent.

The Growing Demand for Electro-Mechanical Testing Expertise

The UK automotive sector, which employs over 168,000 people, faces a seismic shift as 63% of manufacturing roles related to batteries, power electronics, and electric machines will require significant upskilling by 2030.

 With gigafactories like Agratas' £4 billion Somerset plant and AESC's Sunderland expansion set to create 35,000 jobs by 2040, demand for specialists in cell testing is surging.

Key drivers include:

• Battery production scaling: The UK aims to produce 1.4 million EVs annually by 2040, necessitating robust testing protocols for cells, modules, and packs.
• Safety and compliance: Strict ISO standards (e.g., ISO 9001) mandate precise fault diagnosis, thermal management testing, and lifecycle analysis.
• Supply chain localisation: With cathode material demand projected to exceed 130kt by 2030, domestic testing capabilities are vital to meet trade deal requirements.

Core Skills for the Future

Technical Competencies

• Advanced diagnostics: Proficiency in using high-voltage diagnostic tools to identify faults in battery management systems (BMS) and power electronics.
• Material science knowledge: Understanding anode/cathode material behaviour under stress, degradation patterns, and thermal runaway prevention.
• Data interpretation: Ability to analyse test results from cyclers, environmental chambers, and mechanical stress rigs to optimise cell performance.
• Cross-disciplinary integration: Bridging mechanical, electrical, and software engineering to troubleshoot interconnected systems (e.g., cooling, earthing).

Soft Skills

• Adaptability: Navigating rapid technological changes, such as solid-state battery testing methodologies.
• Collaboration: Working with R&D, manufacturing, and recycling teams to align testing protocols with circular economy goals.

Bridging the Skills Gap

• The UK's Electrification Skills Network (ESN) and National Battery Training and Skills Academy (NBTSA) are pioneering initiatives to address shortages:
• Targeted CPD courses: Modular programmes focus on diagnostics, safety standards, and emerging technologies (e.g., Module 6: Diagnostics in Automotive EV Systems).
• Industry-education partnerships: Trailblazer apprenticeships and degree programmes integrate hands-on testing experience with academic rigour.
• "Train the trainer" models: Upskilling educators to disseminate expertise across colleges and specialist centres.

The Road Ahead

To sustain growth, the UK must:

• Expand accessible training: Prioritise short courses in cell electro-mechanics for technicians and engineers.
• Align standards globally: Ensure UK testing certifications meet international benchmarks to attract investment.
• Focus on sustainability: Develop skills in second-life battery testing and recycling processes.

By investing in these areas, the UK can secure its position as a hub for cutting-edge battery innovation, powering both the green economy and high-value job creation.

The future of cell electro-mechanical testing is not just about technology—it's about people. With strategic collaboration between industry, educators, and policymakers, the UK can build a workforce ready to electrify tomorrow.