XT60/EC3 Battery Connector Indicator Cap

thingiverse

This is a battery connector cap for XT60 connectors, with a built-in indicator showing the state of the battery - full, empty, or stored. This design also works for EC3 connectors with some adjustments and careful installation. It's perfect for RC enthusiasts who need to keep track of multiple batteries while flying planes or driving vehicles in the field. The design consists of four parts: two sleeves, an indicator, and a storage cap. I chose to print the inner and outer sleeves yellow to match the XT60 connectors and make them easy to spot when dropped in the field. The indicator should be printed in red and green for clear visibility. The storage cap is black for maximum contrast. It's essential to have precise printer calibration for best results, as there are tight tolerances in these prints. Be prepared to adjust print settings or scale up/down depending on your printer and preferred grip on the connector. To get the best results, follow these printing directions: Print the Outer sleeve with the tiny indicator notches closest to the plate, ensuring good adhesion due to the chamfered edges. The Inner sleeve should be printed with the notches facing up for minimal distortion. The Indicator can be printed flat, and the Storage cap face-down as usual. Assembly is a breeze when done correctly: Lay the Indicator into the Outer sleeve, position it using a pen or pencil, and then press an XT60 connector down to secure it in place. Next, take the Inner sleeve with notches facing down and carefully press it into the Outer sleeve on a hard surface. Press down until fully seated, then flip the assembly over and firmly press the edges to ensure everything is tight. Finally, use a pen clip or paperclip to gently rotate the indicator a few times to loosen it up. Rotate in both directions until you can comfortably turn it with your fingernail like you would in the field. Install on your XT60 connector! The Storage cap snaps onto the entire assembly and can be easily removed by pulling the pointed end and rotating it away from the connector at an angle. The whole cap, including the Storage cap, can be completely removed by squeezing the sides when pulling to keep it connected to the indicator cap.