eLeaf iStick Power 80W "Wireless" Magnetic Charging Dock

myminifactory

This is a relatively simple design for a "wireless"-ish charging dock for an eLeaf iStick Power 80W e-cigarette. The goal was straightforward: as the USB charging port is located on the bottom of the device, I wanted to create a dock that would make it easier to plug in or remove the device without any hassle. However, with one of my old eLeaf e-cigs that had a similar design, I found it challenging to use the dock due to its narrow design, which only accommodated one singular USB cable. So, I aimed to create something more generic and user-friendly, utilizing a magnetic tip USB cable for easier day-to-day use. The complete dock consists of three interconnected parts: Shell: This part attaches directly to the battery pack itself. The magnetic tip of the USB cable can remain attached to the battery at all times, and the shell's primary function is to provide a flat surface around the tip, allowing you to stand up the battery comfortably. It also ensures that the static material surrounding the battery reduces the risk of scratches from repeated insertion into the dock. Notably, there's an additional hole in the bottom of the shell to prevent covering the holes on the device's bottom, which I believe provide some airflow. Dock: The shell slides seamlessly into the top of the dock, which houses the actual USB cable. The dock is designed with a taller profile to accommodate the USB cable's end, allowing for sufficient room to avoid excessive bending and storing slack if desired. A cutout at the bottom enables easy passage of the cable through the dock. I also made the dock slightly taller than necessary to facilitate permanent attachment of the cable's end to the hole using hot glue or tape, although this proved unnecessary with my particular cable due to its inherent tension. Dock Bottom: This part serves as a cap for the dock's bottom and features a matching hole for the USB cable to pass through. Standoffs on the edges prevent the dock from sliding too deeply into the dock bottom. The magnetic tip USB cable I'm using is available here (http://amzn.com/B07GSNNPVJ). The hole in the tip should accommodate most similar cables, but if not, you can easily remix the model by enlarging the hole or adding material as needed. I recommend printing the dock upside down and including support material that touches the bed to ensure a smooth print. Due to my design goals, I couldn't achieve a viable dock without supports, and flipping it upside down minimizes the amount of support material required. I've included my PrusaSlicer 3MF file for your convenience. I purchased two packs of cables and printed multiple docks/dock bottoms and shells so that I could have a dock at work as well. The design has worked exceptionally well for me thus far, with one minor issue: the shell still allows the magnetic tip to protrude slightly due to my printer's unevenness in printing the bottom. However, this can be easily remedied by permanently fixing the cable in place if desired. The tension between the dock and dock bottom provides sufficient force to prevent the cable from sliding out excessively, and pulling the e-cig out of the dock removes the cable slightly, allowing it to return to its original position when reinserted.