I want to mill the contacts out of copper, but I need to figure out how to press them effectively against the batterys
The enclosure will not be sold, when I finish this project I will make it available and you can print it yourself,
I can sell the contacts 
Spring load them maybe?
If done well this could eliminate a huge barrier for people getting into diy esk8
This is what NESE and a few others use. Seems to work alright for most but some members here have had issues with contacts jumping around a bit and burning out.
Thanks for the info. I found this topic thanks to you 
Burnout is what worries me the most…
Not all batteries have the same contact surfaces, plus vibration can also be a problem… but want to try I like the idea…
@IDEA from September I’m going to be conducting some research for 6 months on material selection for 3D printed dampers. Though itll be for high shock/impact applications, I am considering looking into vibration environments too. If I find anything interesting I’ll let you know
That’s what I did. Used my soldering iron to “glue” the pieces together. Has held up fairly well. Added some extra PETG at the joints. You can always cover it with carbon fiber because it isn’t super sexy with the glued joints. I used a soft / thick gasket type of material to give it some room for flex as it doesn’t bend like the deck. But the final shape can be whatever you want.
Pics please!
Just came across this concept which I figured may be of interest to you
Thanks, I was thinking about that too. I wanted to make a plastic (printed) spring, but with a different design, only on one side of the battery
Work on the enclosure has started… description of the construction of a board with such a enclosure here
Reminds me of keith haring and mr doodle
Maybe use some small round magnets that would keep contact to the cell +/- even if the printed spring allows movement or fails.
Interesting idea, I’ll have to see if it works 
Loving all these design ideas, esp having individual compartment so the board can flex… have anyone try TPU? is it too soft to protect the cells?
I think TPU is a very real option. There is a wide range of flexibility out there - even beyond what the stated shore hardness would lead you to believe.
“Hard” TPU has replaced PETG for me when it comes to functional/structural parts. Especially if temperature resistance is a concern.
I have just found a flavor that is a mix of TPU and nylon (which by itself is typically beyond the capabilities of my machine). I plan to try an enclosure with it… but haven’t yet, so actual performance is still just speculation.
Link? 
CC3D 72D Flexible TPU Filament Black 1.75mm 1KG 3D Printer Filament High Hardness High Toughness TPU Filament FDM Printer 3D Printing Material Comparable to Nylon Filament https://a.co/d/15DJMSA
It is VERY hygroscopic. I would consider drying absolutely necessary prior to printing. And it sure doesn’t help that the airtightness of the packaging was definitely lacking.
Note that this material hardness is spec’d in the shore D scale instead of shore A, as is more common. From memory I think that 72D is roughly equivalent to about 102A.
Edited for clarity
Not as hard as the above material, but this also seems to be decent for structural applications of TPU. Have only printed about a kg of it myself.
RANKI TPU Filament 1.75 mm Flexible TPU, 3D Printer Filament, Dimensional Accuracy +/- 0.05 mm, 98A,1kg Spool,Black https://a.co/d/3JaOgKz
@jack.luis has been the conductor on the Ranki TPU train for some time now. I need to order some of that stuff
