Battery Posts with Ni straps for High Currents

thingiverse

3D printed battery posts for a Pb accumulator with either standard EN (TYPE A2) or thinner SAE/JIS (TYPE A) terminals. (pencil) terminals. Can also by used for DIN (TYPE A1) terminals. Can't be used for pencil JIS terminals (TYPE A3). Provided are models for both poles. Design needs M5 screw, M5 nut and two washers for each post. Screw is used for clamping post to the battery terminal and for conncting the conductor's ring terminal. For given current appropriately sized conductors shall have crimped insulated M5 ring terminals. Posts use Nickel strips of size 0.12x8mm. The socket is sized for 4 pcs of such a strip. Strips are mostly covered by the plastic, principle obvious from pictures. Calculated safe and conservative continuous current with 4pcs of Ni stip : 24A (6A per strip). In reality it can be used and heats up acceptably even at continuous 60A (loaded 700W DC/AC inverter). Cheaper Nickel platet steel strip can be also used, but the max. current limit drops by some 40%. Example of usable Nickel plated steel strips (0.12x8mm variant): https://www.aliexpress.com/item/33004336067.html Design is far from ideal, the strips are not easy to be pushed into the slot. Deserves optimisations but it's doable even now. For making the holes for mounting screw it's the best to use V-shaped sharp milling bit in dremel rather than a drill.