Battery Tab Spot Welder Project

thingiverse

These are the 3D-printed parts for my Battery Tab Spot Welder Project (see https://www.youtube.com/watch?v=5kWRZHLDFLo ) This is my own take on many DIY battery spot welder projects out there. Most of them use an off-the-shelf timer or Arduino, but I used a NodeMCU microcontroller since I had the parts lying around. This project reuses a 700W microwave oven transformer with high voltage removed and replaced with a 2V, 350A secondary instead. The main voltage is controlled on its way into the microwave oven transformer using a cheap Solid-State-Relay module. The main box prints in PLA without any support but with a 5mm brim for bed adhesion. The lid prints in PLA vertically without any supports. The front panel prints in PLA lying flat on the bed, requiring support material to fill spaces behind the OLED display and rotary encoder. It should be easy to clean up afterwards. Print three aluminum extrusion clips in PLA using vertical printing with no support. Print two cable grommets in Ninjaflex. Print one hand rest in Ninjaflex. Print one rotary encoder knob in Ninjaflex. Print four feet in Ninjaflex. PLA and Ninjaflex are required. Cable grommets, rotary encoder knob, feet, and hand rest print in Ninjaflex - the rest in PLA. With the exception of the front panel, everything else prints without any support material (supports are built into designs where needed). This project is released under the Creative Commons Attribution Share Alike License. Messing around with mains electricity is extremely hazardous. There are risks of electrocution and fire that can be fatal. This series of videos shows what I did - not how to do it safely. If you decide to undertake a similar project, I accept no responsibility or liability for anything bad that happens to you. Do not attempt this project unless you are fully competent in all areas covered and understand the risks involved. There is also an element of danger in welding batteries, so if you do that, you're doing it entirely at your own risk. If you melt holes in your batteries and they burst into flames, then it's not my fault. With all caveats above, I'd love to see someone else make one the same or even better make an improved version and contribute back code tweaks or 3D design improvements. For changes to the code, please raise a pull-request on github. To collaborate on the 3D-model, you'll need to message me with a Fusion 360 username so that I can give you edit permissions. Here are the relevant links: The LUA Code: https://github.com/jimconner/NodeMCU-Dual-Pulse-Weld-Timer The Autodesk Fusion 360 model: http://a360.co/2sEro9Y