20 cell 18650 pack for electric projects

thingiverse

I'm excited to share this with you as it's my first post. If there are any issues, please let me know so we can address them. I needed a custom 18650 pack for my electric motorcycle project and couldn't find one that fit my requirements exactly. So, I took matters into my own hands and designed my own, just like I always do. The photos tell the story, but to summarize: I used 2.5mm twin & earth copper wire - the same kind you'd use for house wiring - to create the pack. I bent the wire into shape by wrapping it around a 6mm drill first and then using pliers to finish the job. To secure the wire in place, I heated it up and pushed it into the slots, which were designed to be snugly fitted. To add an extra layer of security, you can melt some plastic on the ends or glue them in for added stability. The wire that connects the copper to the batteries is 5 amp fuse wire for the positive side and 15 amp fuse wire for the negative side. While the 15 amp isn't crucial, it was easy to solder so I went with it. The 5 amp fuse is essential, though, as it ensures we don't draw too much power from each cell - after all, these are recycled laptop cells. To get everything to fit on my print bed, I rotated the items by 45 degrees and used support for the 20 Cell Holder.stl file. The lid didn't need any additional support. I'm only drawing around 30 amps with this pack, but it's more than capable of handling much more power. **Print Settings** * Printer Brand: Prusa * Printer Model: Prusa Steel * Rafts: No * Supports: Yes * Resolution: .3mm * Infill: 40% * Notes: After printing, I simply ran some sandpaper over the edges to smooth them out. This was enough to get the lids fitting tightly in place. As a precaution, be sure to test the lid's fit before building your pack.