Ryobi Clone Battery Cover

thingiverse

I have a Ryobi impact driver that came with a 1.3AH battery and I wanted a spare battery with a bigger capacity so I bought a clone, compatible battery that was 5.5 AH. The new battery doesn't come with any protective cover over the terminals and I was worried about it in the tool bag shorting out on something so I designed in Fusion360 a custom battery cover to fit the clone battery perfectly. This cover will not fit an original Ryobi battery, due to its slightly larger dimensions. The cover comes in two parts to minimize support material requirements during printing, which made the process much smoother. I printed the cover in PETG, a material that I find works well with superglue for bonding purposes. However, I also decided to use my soldering iron set to 300 C to weld around the inside edges of the cover, just to add an extra layer of durability and prevent it from breaking in the tool bag. The result turned out great. I plan to create a version of this battery cover that fits the original Ryobi battery sometime in the future, as I believe many users would appreciate having a protective cover for their spare batteries as well.