Nice test. nice clean fingernails
You think repeatedly getting the prints to an increased temp but still below the glass tradition temp could warp the print and relieve the compression? Be cool to see a repeated test and somehow gauge the compression after. Maybe just ride it and see if the resistance is increasing beyond what the little amount the cells would increase
Damn that’s some nice gear! So jelly.
My 2 cents. I think electrically everything is up to and beyond specs. The unknowns are the mechanical properties, especially under tension, heat and vibration, over time.
The test is awesome though!
EDIT for grounding braid wire, I find mcmaster has a nice list with specs, and decent prices.
Scroll down to “Grounding Braid”
Whoops I typed this out but never hit reply.
I was doing the test at a electronics lab on college campus. I wish I have all that stuff. I want to test mechanical properties as well. If you guys knows how I can test that I’ll do it. I love McMaster but they don’t have the right 3/8" ~10mm and a good thickness available. Their price aren’t always the best for uncommon items and they use the fastest shipping and then slap you with the shipping cost after.
@Hummie I should dig deeper for PETG spec. I choose petg bc it has higher glass temperature that PLA and more flexible than ABS, which help with compression. Im not entire sure about repeated heat under glass temp damages the integrity of the shape. Not to mention that I did the test at 60A and I believe a normal load on battery is about 15-30a continuous on a dual setup and peaks to whatever your max Batt Amp is when you acelerate.
I can put together a pack with already dead cells and do a few heat cycles in a toaster oven.
I’m literally waiting on this to start a build.
Gonna make an update later. Stay tuned. Here’s some pictures from beta tester chat.
What chat is this?
Privalaged chat 
Update 11/21/18:
I have been using the current design for the past few weeks in my 13s Hummie Build. Although I’m typically only ride on BaeSk8 group rides, our group ride can get quite intensed if you are at the front of the pack pushing 28mph uphill and doing 30+ on flats. and going up Twin peak at full throttle.
there are section with repeated cement gaps and rough street, also I rode on a already terrible road and there was hella small rocks(probably fell of some truck that day) to the group ride. So if your cell holders are properly padded they have no problem dealing with vibration.
[usable telemetry files] (if you wanna throw some metr module at me, you will get better telemetry)
Beta Testing
We have a few beta tester signed up for testing the current design with copper braid. as you read, these copper braid is way over spec our application and iti will stay this way. I am printing out single stack, 2s modules and stagger stack modules for these guys.
I’m confident in the compression and safety, but I know these will take a bit longer than NESE to assemble and would like to hear what they think about the process of putting them together. I’m trying to make these as noob friendly as possible so if you can follow instruction you an build a pack.
Since I already have all the dimension nailed down. it’s quite easy for me to populate all the configurations you will ever want.
single stack, aligned double stack, stagger stack
keep it under 99Wh. multiple S modules. (single stack, double stack however you want)
Working on improving modularity
I’m looking to use ring connector in the next iterations to improve modularity. idea is to quickly connect/disconnect module by loosening the one end of the module and inserting ring connector crimped to the positive sided braid around the first terminal button of negative side of next module
NEW IDEA!!!
Gauging size of market interest and demand for scalability
I need to know how many people are interested in using these cell holders instead of NESE or spot welding services? A set of 12s4p (using 2s4p modules) took about 18 hrs to print at the moment and nowhere scalable with 3d printing. If there’s enough demand, I will make a silicone mold or even design something for injection molding for large quantities.
Pricing: i’m figuring out how much I should price these things and where they are placed in the battery market.
AFAIK spot welding service cost about $200ish in labor. with the advantages of taking off individual cells to replace them and modularity and compactness over NESE, these cell holders I hope to price them low if I can get produced in quantity.
This is what you would expect to get for a 1s4p module + the braid ofc. with the current design and it will only get better.
I’d say it is definitely worth 80usd if they are made from a silicon mold for a 12s6p setup. Because I ride 12s6p still.
If these prove to be reliable over time I’m definitely interested, do you plan to offer a hardware only pack? Lots of people can 3D print the holders at home
I guess I can do that too. I chose to use common parts to keep cost down. It’s just I can get these stuff in bulk to keep cost lower and some stuff takes a while to ship from China.
Exactly, cheaper and easier for everyone to get all from one place
As I understood you plan to go to injection molding in the future?
I think this comes down to how popular the modules will be. Even then I would assume that it would be on the popular build types (4/5p).
@Winfly I was thinking here, injection molding will be expensive for sure, what if you could do a hybrid construction? Laser cutting is pretty cheap, you could have a reinforcement stainless steel plate at each side, with some longer screws one side could be threaded to further reduce the number of components
This way the 3D printed pieces would only be used to position te cells and have the bump to guarantee the compression on the right place
Another upside is that if the steel plate thickness is calculated correctly it will be light and works as a spring, no more worrying about compression set
I agree with the injection moulding being too expensive, ecspecially since he’ll need multiple different moulds made
Thank you for your suggestions. Quite an interesting approach I didn’t think of.
I ran made a spreadsheet today to see what’s the reasonable cost for everyone. I’m trying to raise fund to increase production through casting or injection molding, and support further development cost. I spent way too much money ordering the wrong stuff.
As of now, It will take me a day to print a set of 12s4p . That’s no where close to being sustainable. Because I will still be printing these I’m doing an early cost ended up higher than I wanted to be.
Settled cost:
You will have the option of mix of 1s4p and 2s4p modules for cutomized flexibility at different part of your board. Pieces will be cleaned up, Inspected and test fitted before shipping out.
Dimension of 1s4p module is 22h x 73w x 76l 2s4p saves 1mm in length. Pic later.
Other configurations:
Add-ons:
Offer will be availabled once beta tester receive their units within 2 weeks and provide user feedback and pics.
NESE 10s4p modules = 90 EURO (with 4p modules) and 84 EURO (with 2s4p). + Shipping
Advantages over spot welding:
Disadvantages:
Advantage over NESE:
Disadvantage vs NESE:
As for promised releasing 3d model for this project. I dont thinking this is the right time yet.
I promise, once I overcome production logistics and begin higher volume production using better method. models will be available to public
Please express your Interest and inquiry here.
And keep discussion on this post
Finally found some Ring Connectors that is the right size so that it preserve the form factor. still need to trim the crimp length by half but this will do.
On the other hand. I’m getting some of these made by a copper company in china. pressed copper on both sides with braid running along the whole length. It will be nickel plated and then pressed to make the buttons for contacts. since the MOQ is high I’ll only be ordering these for 4p options.
Making Custom 4P modules for the HAYA Deck. Will be test fitted on @sofu’s new acquired HAYA.
will be oriented as such and featuring small holes for 24Gauge balance wire. (should fit 3 at the rectangle and 2 more holes at the corner
i’m working on a custom enclosure with swappable battery on everyone’s favorite short deck SPUD / TAYTO
12s3p
It’s slightly angled to match the concave of the deck
Realized I need clearance for the kicktail to actually do anything. lmao. 12s3p is a little too big but I will still keep mine this way. maybe offering 10s3p or 12s2p in the future for the swappable to make sense.
Going to print a 2 piece enclosure and then either make a silicone mold or Fiberglass right on top.
Since I was busy with school when I was last posted about selling them. and told everyone to hold off. how many ppl are interested to still?
0 voters
Price chart is as such.
+ $7-13 US shipping. , will figure out international shipping when you ask me
I know I changed it a few time but this makes more sense for me.
Havent been posting for a while but here are some pictures from me and my lovely Beta Testers: @Wraith, @J0ker3366, @Friskies, @neiru37
Rebuilding my 13s4p with 2s4p modules
Compression leaving a small imprint on the cell contacts
Packing 10s6p modules with some extras into USPS small flat rate box
@Friskies’s 2s5p modules
@J0ker3366’s 10s6p modules partially assemble
@Wraith’s 10s6p modules
@neiru37’s 12s4p with custom xt30 connectors between 2s4p modules
These look amazing, I especially like the last pic with the xt-30. By any chance do you have the dimensions of a 1s3p module, I feel as though it must be here but can’t find it
