ModuLOL - 1S - Modular Battery System - 18650

Welcome to ModuLOL,

1. Project overview
2. Disclaimer
3. Print Part 1 - The Case
4. Print Part 2 - The Fillet
5. Print Part 3 - The Lid
6. Print Part X - Adapter Geometry

1.  Project overview

The idea is to have a battery pack which can be adapted to a variety of electrical devices. The connection between battery and device is realized with magnets. The current is also been transmitted over the magnet connection. 

Since most of the adaptable consumers I used are quite unique (e.g. little motor from a drone or a 1W led with lense). Therefore the project aims to give you the adapter geometry and you can design your own gadget / flashlight / bikelamp? / Powerbank? / Laser?. (however I will share my adapter models without comments)

I tryied to work with as much standard parts as possible. Unfortunately the switch and the spring (see BOM at 4.) are quite unique. If you have a smaller switch you can print a small housing and place it there instead of my used one. 

For step by step tutorial check the attached PDF. 

2. Disclaimer

I am not an electrical engineer. My background is more on the polymer side. So please only build this if you can estimate the risk, especially in terms of electronics. (e.g. LiIon Battery, soldering, max current per wire mm², resistors for high voltage LEDs…)

3. Print Part 1 - The Case

BOM: 
M3x10 hexagon socket screw (2x) !non-magnetic!, 
Nickel Strip 93x8x0,15 (2x), 
Magnets D8mm Thickness 3mm (2x), 
18650 Li Ion Battery, (e.g. ICR18650-26J)

DESCRIPTION:
The battery case has space for the fillet (BMS-Board + Switch) and the 18650 battery. Alongside the battery, two nickel strips are pushed in. In the front, two magnets are connected to the nickel strips. At last the lid is screwed with the M3 screws to the case.

PRINT INSTRUCTIONS:
ABS 0,12mm layer height, 12mm/s speed, no support, I used 0,4 Nozzle, I used ABS

4. Print Part 2 - The Fillet

BOM: 
BMS Board TP4056 (I used micro USB), 
Switch “Eledis SED3GI-2”, 
Nickel Strip 40x8x0,15 + 34x8x0,15, 
Spring D6mm length 5,5mm, conductive

DESCRIPTION:
The fillet holds the switch and the BMS board. Nickel stripes and some cables will do the electronic. 

RINT INSTRUCTIONS:
0,12mm layer, I used support here, nothing special

5. Print Part 3 - The Lid

The Lid is the easiest part. for the magnet place you hay have to use a cutter to reduce the first layer edges.

6. Print Part X - Adapter Geometry

Print the bottom part of the 1W LED for a start. You can design your own “TOP LED part” with your own unique electrical devices.