16Ah Custom DeWalt Battery Enclosure

This is an enclosure for a 5s4p battery pack with 21700 cells to build a custom 16Ah battery compatible with DeWalt brand tools and chargers.

I used a PCB from Amazon to wire the balance leads, it comes with a charge indicator board too which is nice. It also includes a plastic case that I will probably never use, I'm sure you could find the PCB sold by itself for cheaper somewhere. I used hotglue to secure the PCB and charge indicator in place and it works great.

I changed the top quite a bit compared to the original and most significantly I added a slot for the charge indicator. Both the bottom and the top are obviously quite a bit bigger to fit 20x 21700 cells (staggered).

I included a cell organizer to hold the cells in place which makes building the pack a lot easier and keeps the pack nice and sturdy. The fit is almost perfect but I just tweaked my flow a tiny bit to get it nice and snug/ Print two of them and your pack will be very sturdy.,

So far PLA has worked fine for me, but PETG will offer more heat resistance if you notice the PLA getting soft during heavy use. Print the gasket in TPU for a nice seal. Secured with four M3 x 20mm screws.

PCB link - https://www.amazon.com/dp/B07VHBQK46?psc=1&ref=ppx_yo2ov_dt_b_product_details

You can purchase these batteries completely assembled here