Use

The cell holders will hold the cells in position so that there is no strain put on the spot welds. Our cell holders are made from 3/8" Acetal. Acetal was chosen mainly because of its ease of machining.

We will have 2 different cell holders in the car, one for the top of the modules and one for the bottom of the modules. The top module has holes for mounting the gusset plates to. The bottom plate has location features to allow placement in the box, and will restrain it in horizontal motion. The two acetal plates are connected with 60mm aluminum standoffs.

Relevant Specs

Acetal (not Delrin), 3/8" thick

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We will be getting our acetal from Piedmont Plastics in Kitchener. They were the cheapest source we found for 3/8" black acetal sheets. The next best option is Plasticworld.ca in Toronto. The material will come in a large sheet and will need to be cut before machining. We are getting a full 4x8 sheet of acetal cut in to 8" x 6" pieces.

Manufacturing

The acetal will be machined to shape on the HAAS VF2 in the student machine shop. Brian and Graeme have been super helpful getting set up with this.

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Then round off the edges on the bottom piece, and the bottom edge of the top piece to have easy module insertion and removal. Probably using a 1mm radius router bit. Doesn't have to be a perfect 1mm radius, but would be nice. A router sled and a bit for the Dremel will need to be acquired / made.

Manufacturing Files

These are the original manufacturing files sent to get quotes for machining the capture plates:

Linamar

Linamar has offered to 3D Print some parts for us. Given the quotes we received for machining and the quality of the 3D printed prototypes that we have been able to produce on our Prusa MK2.5S, we think this part would be a great candidate.
Here are the files we should send to them (Updated Jul. 14, 2020).