Stacked 4 AA Battery Holder

thingiverse

This design is a remix of mrbenbritton's AA battery holder concept, with a unique twist. I've taken his idea for attaching jumper wires and reworked it from scratch in FreeCAD. The goal was to create a compact 4-battery stack that outperforms linear designs. To achieve this, I designed the holder with .8mm walls, which provides optimal printing results when using a .4mm nozzle. Printing time is approximately 1 hour and 20 minutes, utilizing .15 layers. Due to the thin walls, infill settings are unnecessary; brim, raft, or supports are also not required. The design accommodates Eneloop Pro AA batteries, which have a slightly wider profile than standard AA batteries. The length of the holder is tailored for use with 22-gauge single-strand wire for jumper connections. If your batteries don't fit perfectly, you can experiment with lighter or heavier wire to achieve a snug fit. For series wiring configuration, refer to the photos provided. The back side of each bay features top-to-bottom wiring connectivity, while the front side showcases side-by-side connections between the top two batteries. The output terminals are conveniently located on the bottom two batteries.