Battery Spot Welding Fixture - 18650, AA, AAA

thingiverse

I designed a device for welding batteries that includes holders for 18650, AA, and AAA batteries. I based it on an earlier design: www.aliexpress.com/item/18650-battery-welding-fixture-18650-battery-fixed-clamp-18650-Battery-Fixture-Clamp-for-2-6-batteries/1907351540.html. However, this early design was hard to work with due to movement and pressure on the batteries. AAs are particularly difficult to stabilize. To address these issues, I made adjustments, creating separate compartments and a larger base that gives enough room for passing wires between battery connections. The device is designed so it can be flipped over and batteries accessed from below as well. Both sides now have small slits for use with clamps that secure things firmly in place. Depending on the performance of your 3D printer, you might need to slightly scale up or down by 1% to ensure a snug fit. I adjusted my design settings in Simplify3D by entering -0.05mm in Horizontal Size Compensation so I got a slightly looser hold than originally designed. Battery thickness and wrapper size play important roles here too. A minor amount of filing might be needed if the seams are not done well, even with some good printer control.