Some people here have shared their ideas for 3D printed battery cell holders (e.g. NESE & @Winfly’s compression pack) and also there are people who print their enclosures. I thought why not combine the two.
This is my idea of a single 3D printed part which serves as an enclosure and houses a 10S3P battery, no spot welding required. It uses the NESE tabs to connect the cells and to provide the compression for the contacts.
The size of the part is a little under 200 x 200 mm and so could be printed with almost any 3D printer. This is also the reason why I chose 3P configuration. The outer dimensions of the part are roughly the same as an Ownboard enclosure which only holds a 2P battery.
Cells don’t need any soldering and can be swapped when needed. The part was designed 3D printing in mind and so it prints in one piece and doesn’t need supports.
This particular enclosure is designed to fit a Loaded Vanguard. I’ve yet to decide how to mount the part to the deck but I’m leaning towards to embed some inserts to the enclosure and bolt it down from the top of the deck.
The grooves behind some of the tabs are for routing BMS wires. Two larger grooves on the sides are needed to connect two 3P tabs together by soldering some large gauge wire between them.
I’m also thinking to make some kind of a lid to separate the BMS area from the cells. Something like this:
At the moment I’m not sure if and when I’m going to print and test this. Just thought to share my idea and maybe get some constructive criticism from you guys.
If I were to print it I would use Colorfabb XT (clear) which is the most durable filament I’ve ever used that is still very easy to print. I’m sure there are some forces from the battery compression and so the part has to be able to take it without cracking. I made sure there’s a lot of material around the cells in the design.