Cosplay Lithium-Ion Battery Box

thingiverse

Power! Many cosplayers crave it, adore it, rely on it. This is a compact power supply box for a high-energy 26650 lithium ion battery. It features a small rocker switch and ample space to accommodate a 5W resistor or tiny constant current limiter. The battery powered 50 brilliant white LEDs with a brightness of 10,000mcd for about 8 hours. The LEDs were arranged in parallel, and the resistor was carefully calculated based on the voltage and current requirements of the LEDs used in this project. To ensure optimal performance, you'll need to adjust the resistor according to your specific LED power needs. If you use a constant current limiter, you can determine the maximum number of LEDs it can support by its current rating. Here's what you'll need for this project: * Lithium ion batteries and charger: $26.88 (100 pieces) * 120 degree white LEDs: $5.65 * 20 gauge hookup wire: $4.97 * 1/4" copper tape: $12.30 * 301Ω 5W Sandstone resistor: $0.36 * SPST Micro toggle switch: $1.17 The total cost for the power supply box and lighting is approximately $20, excluding the battery cost. Some of these items are more than what you'll need for this project. Additional materials include a spare 2.1mm barrel jack and plug set, bare 24 gauge copper wire, a tie wrap, and heat shrink. The copper tape is used for the battery contacts. I recommend soldering the pigtails to the copper tape before removing the adhesive tape and installing it. The wiring diagram is straightforward: we used bare copper wire to connect the LEDs together. Adjust the spacing according to position and location within your costume or headdress. Important Safety Note: Be cautious when working with lithium batteries, as they can be hazardous if shorted out. Always perform a visual inspection before connecting the battery to your wiring harness. These photos showcase my daughter's Devil Mercy costume she wore to Blizzcon 2016. While I provided guidance on the power supply box, she expertly handled the soldering and wiring for the costume. Print Settings: Printer Brand: SeeMeCNC Printer: Rostock MAX v2 Rafts: Doesn't Matter Supports: No Resolution: 0.2mm Infill: 20% Post-Printing Assembly: There's a punch-out on the side of the battery box that can be cut out with a sharp knife, allowing you to remove the battery by inserting your thumb. Before installing the copper tape, check the fit of the battery. It should fit snugly but not too tightly. Sand down the battery connections if they're too tight. Next, pass the black wire through the channel between the outer wall and battery post. Then, pass the red wire behind the battery post and up to one of the power switch's connectors. Connect a short length of wire from the other connector of the switch to one end of the resistor or current limiting circuit. Keep your wires as short as possible to maximize available space. Pass the barrel connector through the hole at the end of the battery box, securing it with a tie wrap. Connect the black wire from the battery post to the barrel connection of the 2.1mm plug. Finally, connect the remaining end of the resistor or current limiting circuit to the tip connection of the 2.1mm jack. Insert the power switch into its socket and press the resistor into place. If necessary, use hot glue to secure everything inside the cavity. Before inserting the battery, test the connections to ensure there are no short circuits. A short can easily heat up the plastic battery posts, causing them to melt.