Waterloo BWC — EV Battery Module & Cooling Integration.
Supported mechanical design of a competition EV battery module through SolidWorks CAD, cell packaging, busbar routing, cooling-plate integration, clearance checks, and manufacturability reviews.
Designed EV battery-module CAD updates that balanced electrical routing, thermal integration, manufacturability, and pack-level fit.
On Waterloo's Battery Workforce Challenge team, I contributed to the Vehicle System Integration workstream for the EV battery module that forms part of the team's larger competition battery pack. The project required translating module-level requirements into a manufacturable CAD design that could support cell packaging, busbar routing, cooling integration, sensing access, structural support, and assembly constraints.
My work focused on SolidWorks CAD updates to the battery module, including cell layout adjustments, busbar geometry refinements, cooling-plate compatibility, fastener and bracket clearances, and packaging checks against surrounding pack and enclosure geometry. The goal was to move the design from a conceptual model toward a more buildable module that could be reviewed, manufactured, assembled, and serviced.
The project gave me direct experience balancing mechanical, electrical, and thermal requirements in a competition EV environment, with iterative feedback from electrical, thermal, manufacturing, and vehicle-integration subteams.
- 01Owned the SolidWorks CAD workstream for the battery module, building parametric cell arrays and iterating on packaging variants against electrical, thermal, and manufacturing constraints.
- 02Redesigned busbar geometry and routing to improve current capacity, assembly access, and serviceability while keeping interfaces compatible with the existing pack enclosure.
- 03Integrated coolant pathways through the module and validated clearances, fasteners, and serviceability against chassis and enclosure references in weekly cross-team design reviews.