Fusion360 Battery Pack Script

[ducktaperules]

Nah that’s just bad grammars

[Benjo]

Didn’t spot it because I didn’t know who or what that is

[Venom121212]

So for the cell spacing on larger cells, do you recommend using cell diameter plus 1-2mm?

[Venom121212]

Found it in the wild

It was a moral dilemma clicking OK

[Acido]

I would recommend also adding a fishpaper thickness between the p groups, its around 0.5mm or so thick i can measure tomorrow, it adds up significantly when the space is tight

[Benjo]

I am just getting into the topic of actually building a pack, so forgive me if that’s a stupid question: Why do you need fishpaper between p groups if you’re building a solid, non-flexible pack that is all glued together?

[Acido]

Just as an extra safety, if 2 cells from different p groups make a connection where they shouldnt then a short circuit happens because of different voltages

[Benjo]

Ok, I see that. But it is slightly overcautious as there shouldn’t be any vibration and abrasion between groups if they are glued, right? Or is this absolutely recommended?

[Acido]

All depends on the glue, temperatures of your glue gun, amount of vibrations, how the battery is mounted etc

Why not spend 3$ more and use 5mm more of space for that extra peace of mind?

[Benjo]

If at all it’s the 5mm and not the money But I will note that and try to incorporate it, thanks

[ducktaperules]

You willing to bet your house on “shouldn’t” ?

Heatshrink is a bad against abrasion, That’s why we have fishpaper. Might as well use it.

[ducktaperules]

Just cross-posting this here because i thought it was relevant and usefull.

@ducktaperules

My lazy diy battery pack.

The goal here was to make a printed cell holder so that I don’t have to do all this gluing insulating fish paper boring bullshit.

before someone states the obvious . . .YES . . . i know i can buy one and its probably cheaper. however wanted one a particular size and shape and in future i might want to add my own geometry onto this part. im done with waiting for parts during the pandemic.

Design It:

The main thing that makes CAD for this super easy was an idea i had to abuse my Fusion360 Battery Pack Script

First step is to generate the cells. I used 18650 so used 18.6mm diameter and 19.4mm as the spacing (same as standard cell holders)

Next we made another pack where the cells are a few mm narrower but also a few mm longer. this will be the space needed to weld the ends of the tabs.

Then i make a 3rd pack which will be the actual cell holder. The width is the cell width + the desired wall thickness, in my case i used a width of 20.2mm. (20.2 - 18.6/2) = 0.8m wall thickness which is 2 passes of my 0.4mm nosle. height is the desired height of the cell holder, i went 10mm.

i then move the black group down a fraction so that i get a lip on the bottom to hold the batterys in place. I used 0.4mm so that its 2 layers when i print.

Finally i use a combine on the black part to remove all the other cylinders

leaving me with a finished holder. it could be printed as is but i added some fillets for fun.

For the other side i just mirrored this part

Print It

I made 12s6p cause that what cells i had but you should be able to fit up to 12s10p on the Ender 3 print bed.

I printed using PETG for a slightly better temperature resistance and used a brim to make sure things stayed down during printing.

Clean up is not super critical as it wont really be seen inside the pack.

Once you have done both parts (careful cause they are not the same) you can fill it with your cells. I used some recycled E-bike cells i had laying around.

Weld It

To make this super easy im using 25mm nickel and my bodgy malectrics setup.

Nickel seems to push down and make contact well enough. I probably went overboard with the welds but why not.

On the other side I let the positive and negative nickels overhang so that i can solder larger cables onto these tabs.

Im planning to print a case for this but it think a pack using this construction would easily fit in a peli case or similar.

[Creavenger]

Awesome! Definitely going this route when I make another battery in the future

[Acido]

Does anyone elses script just bugs out an keeps loading?

[ducktaperules]

If cell size and spacing are the same then it has to do lots of unions And can be slow. I have found that when the spacing is bigger than cell size it runs much faster.

helpfull?

[Sharky]

omg this thing is sooooo nice work man where can i donate something??
im serious about tht

Thx sooo much man this makes searching for a case soo much easier!!!

[TheRef]

Dude this is so sick! Thank you!

[ducktaperules]

If we ever meet, a pint will do

[Sharky]

Mnn this tool i sooo nice i just created a cell holder for 80 21700s

the dimenions are 151x224x10
Had to change the cell layout to get it to fit the layout will look like this then for a 16s5p pack

and the inner dimensions fo the Pelicase 1200 are 181x235x105
so it will be a snug fit printer will run today

A pint off course where are you from man?
Im from Austria (europe) maybe at one event we could meet someday.

KR and thx again

[Komamtb]

I wanted to get into fusion360, but heard free options now are somewhat limited? Could anyone chime in?