Battery Manufacturing

Introduction

The surge in electric vehicle production and the growing demand for sustainable energy solutions has placed battery manufacturing, particularly gigafactories, at the forefront of America’s growing industrial landscape.

As of 2024, more than 30 gigafactories are either operational or planned across North America. A 2025 study by the International Council on Clean Transportation projects the U.S. battery industry will create between 84,000 to 125,000 domestic jobs by 2032. Leading companies in this rapidly evolving field include Tesla, LG Chem, Panasonic, CATL, and Northvolt. New regions referred to as “the battery belt” are emerging across the Midwest and Southern USA.

Battery manufacturing involves the production of critical components such as lithium-ion cells, battery management systems, and a recycling ecosystem. This sector not only requires expertise in engineering and materials but also demands proficiency in innovative manufacturing techniques and automation. As gigafactories scale to meet the increasing global demand for batteries, the need for innovative, first of their kind training programs grows as well.

While many aspects of electric vehicle manufacturing overlap with battery manufacturing, distinguishing characteristics exist that warrant unique occupational roles. A significant increase, projected to be sixfold, in domestic battery demand is anticipated by 2030.

In 2024, the Center for Automotive Research published their preliminary report titled Examining Workforce Needs for North America: Battery Industry Education and Training Needs Assessment (BIETNA) where they surveyed more than 188 companies across the U.S. to understand their skills needs and workforce projections. The report offers valuable and timely insights into how companies across the United States are looking to partner with training institutions.

Chart: Projected U.S. battery pack demand

Chart: Planned U.S. battery facilities and production capacity

Important Trends

Percent of roles in a battery facility that do not require less than a bachelors degree

Soft Skills – Not to be Overlooked

Many graduates enter the workforce with strong technical knowledge but lack the necessary soft skills that employers increasingly value. This gap can lead to misunderstandings and decreased productivity, affecting overall team dynamics and a healthy workplace. For early-career employees, mastering these skills can be a significant barrier to success, therefore training initiatives focused on soft skills is essential for career advancement and retention.

What does soft-skills training look like?

Integrating soft skills into curriculum: Courses should focus on effective communication, teamwork, conflict resolution, and leadership skills tailored to specific roles in battery manufacturing. Additionally, basic organizational tools should be covered like creating a bank account, how to organize reliable transportation to work, how to create a lunch that fuels you for your day. For many early-career students entering the workforce, these are foundational gaps that greatly impact their ability to contribute to their new roles.
Workshops and seminars: Regular workshops and seminars on soft skills should be included in all programming. Topics could include negotiation tactics, emotional intelligence, and managing a diverse workplace. Austin Community College’s “Adulting 101” program exemplifies how introductory courses can equip students with necessary life skills before entering the workforce.
Mentorship component: Ensuring the on-the-job training mentorship component promotes skill-transfer while fostering a culture of continuous learning. Mentors can provide guidance on soft skills application in real-world contexts.

Colleges’ Role in Industry Retention

Focusing on upskilling and apprenticeships is vital for employee retention, particularly in regions that may lack specialized skill sets. By training individuals who are already rooted in the community, colleges can help industry partners foster loyalty and commitment, reducing turnover rates significantly.

Why Train Locally?

Community connection: Employees who are born and raised in a community often have a deeper connection to the area, fostering a sense of belonging and commitment to local employers. This intrinsic belonging can lead to longer tenures compared to employees who relocate and may view their employment as temporary.
Reduced relocation challenges: Hiring and relocating talent from outside the region presents numerous challenges, including logistical issues, financial burdens, and cultural adjustments.
Building a sustainable talent pipeline: By establishing ongoing training partnerships with local businesses, employers and colleges can create a robust talent pipeline within their communities.

An example of this trend can be seen in the tool & die field, where only 2% of the workforce is under the age of 35 and the industry is geographically concentrated in just 2-3 regions across North America. However, apprenticeship programs that train local students in areas outside of these clusters are now contributing significantly to the tool & die workforce. In the past, companies faced challenges in relocating individuals to states like California, Texas, and New York, where the industry was comparably smaller. Today, these local training initiatives are helping to build a sustainable workforce, reducing the need for relocation and fostering talent within the community. This is extremely relevant to the growing battery industry as skill sets are wholly new or require adapting of existing jobs.

Promising Practices

Making EV Batteries: Operator Registered Apprenticeship Program Curriculum at Kansas City Kansas Community College

The Kansas City Kansas Community College (KCKCC) Operator Registered Apprenticeship Program (RAP) will focus on making electric vehicle batteries. This is to launch and/or expand RAPs and increase RAP opportunities for programs that lead to RAP enrollment. The RAP is a 16 credit certificate program consisting of courses which are a subset of the Automation Engineer Technology (AET) Associate of Applied Science degree program. For the purposes of this partnership with Panasonic Energy Corporation of North America (PECNA) and AACC, the courses selected are to accelerate the skills needed/required by PECNA’s Skill Machine Technician 1. This certificate will become a national model for all community colleges to learn from as AACC shares through its channels and membership.

AMFT 0100 Safety OSHA 10: 2 credit hours
AMFT 0101 AC/DC Circuits: 4 credit hours
AMFT 0112 Industrial Fluid Power: 3 credit hours
AMFT 0121 Programmable Logic Controllers (PLC): 3 credit hours AMFT 0150 Electric Motor Controls: 3 credit hours
BLUE 0101 Freshman Seminar: 1 credit hour

Upon mutual agreement by KCKCC and PECNA, the courses listed above may be modified to serve the needs of the students and the apprenticeship program.

KCKCC will provide the curriculum, classroom and lab space, equipment and supplies needed for the RTI portion of the apprenticeship program. All curriculum developed by KCKCC shall be credit-based. KCKCC hired Panasonic employees as adjunct instructors. Hiring Panasonic employees helps with instructor shortages. Career and technical education (CTE) programs often compete with high-wage industry salaries. Also, hiring Panasonic employees enhances the contextualization of the training.

Students in this program will be hired by PECNA prior to beginning the program. After an orientation period, the program will feature an 8-week, front-loaded education model on-the-job training. One or more PECNA production employees will be assigned as mentors for each cohort. Mentors will ensure students continue their learning experience at work using instructional materials and evaluations provided by the program.

This apprenticeship program contains six core components:

On-The-Job Training
Related Technical Instruction
Employer Mentorship
Progressive Wage Gains
Occupational Credential

Kansas City Kansas Community College Program Overview:

What students will learn

Review and understand the fundamentals of electric vehicles
Get an introduction to EV production
Cover assembly, safety, and quality best practices
Discover key details around electrical units and battery components

How students will benefit

This industry-recognized and industry-validated professional certification gives individuals an advantage
Validate knowledge against industry standards and show their skills are current
Enhance their career opportunities with the EVF certification to gain a competitive advantage in the job market
Set themselves apart from their colleagues
Demonstrate a commitment to their career and continuous improvement
Earn a portable, industry-recognized credential that travels with them throughout their career

Syllabus

1. Lockout/Tagout Procedures	26. Introduction to CMM Arms	51. Quality and Customer Service
2. SDS and Hazard Communication	27. Introduction to Laser Trackers	52. Electrical Units
3. Hazardous Materials Handling	28. Structured Light 3D Scanners	53. Safety for Electrical Work
4. Bloodborne Pathogens	29. 3D Laser Scanners	54. Wire Harness Components
5. Fire Safety and Prevention	30. Introduction to Additive Manufacturing	55. DC Power Sources
6. Ergonomics	31. Additive Manufacturing Safety	56. Battery Selection
7. Arc Flash Safety	32. The Basic Additive Manufacturing Process	57. Introduction to Welding
8. High Voltage Safety	33. Additive Manufacturing Methods and Materials	58. Introduction to Welding
9. Machine Guarding	34. The Additive Manufacturing Supply Chain	59. Overview of Soldering
10. Light Curtains Overview	35. Design for Additive Manufacturing	60. Introduction to Automation
11. Lean Manufacturing Overview	36. Additive Manufacturing Materials Science	61. Introduction to Smart Manufacturing
12. Quality Overview	37. Additive Manufacturing as a Secondary Process	62. Introduction to the Industrial Internet of Things
13. Intro to OSHA	38. Additive Manufacturing as a Secondary Process	63. Introduction to Digital Twin
14. 5S Overview	39. Robot Safety	64. High Energy Batteries
15. Cell Design and Pull Systems	40. Robot Application	65. Lithium Ion Battery Handling & Safety
16. Metrics for Lean	41. Robot Axes and Pathways	66. Introduction to Electric Mobility Manufacturing
17. Total Quality Management Overview	42. Introduction to Collaborative Robots	67. Overview of Electric Vehicle Components
18. Value Stream Mapping: The Current State	43. Essentials of Communication	68. Intro to Adhesive Bonding
19. Value Stream Mapping: The Future State	44. Conflict Resolution Principles	69. Intro to Coating Composition
20. Continuous Process Improvement: Managing Flow	45. Conflict Resolution for Different Groups	70. Introduction to Assembly
21. Continuous Process Improvement: Identifying and Eliminating Waste	46. Conflict Resolution for Different Groups	71. Abrasive Finishing Processes
22. Blueprint Reading	47. Managing the Diverse Workplace	72. Introduction to Mechanical Systems
23. Basic Measurement	48. Personal Protective Equipment	73. Introduction to Fluid Systems
24. Nondestructive Testing	49. ISO 9001: 2015 Review
25. Inspecting with CMMs	50. IATF 16949:2016 Overview

Stay Connected

Battery Show North America – North America’s largest battery technology trade show with additional regional meetings.
NAATBatt Annual Conference – The annual meeting and conference of NAATBatt International, the trade association for advanced battery technology in North America.
Advanced Automotive Battery Conference – During this annual meeting, experts review the status of automotive battery technology and provide informed glimpses into the future.
Battery Recycling & Reuse USA – The annual meeting of leading automotive manufacturers and battery recycling experts.
Gigafactory Summit – During this annual meeting, industry leaders in EV manufacturing meet with gigafactory planners and commissioners to explore the latest technologies shaping the future of EV battery production.