Module Manufacturing Guide

This document is intended to contain step-by-step instructions for those manufacturing the battery module/

3D Printing

Print the parts required using the G-code linked. Make sure to use the g-code for the right printer and filament.

Top Cell Holder:

Prusa i3 MK3S+

Prusa Mini+

Bottom Cell Holder:

Prusa i3 MK3S+

Prusa Mini+

Bottom Cover:

Prusa i3 MK3S+

Prusa Mini+

Module Holder:

Prusa i3 MK3S+

Prusa Mini+

Module Top Plate:

Prusa i3 MK3S+

Prusa Mini+

Visual Inspection
Check the fits for your print by checking if the correct hardware fit into them and measuring with calipers.

In the module print validation box there will be one of each fastener, a cell, and calipers. We will use these to check if a print is acceptable.

Items needed for tolerance check:

Use calipers to check that the diameter of these 4 holes is 5.1 mm ±.5 mm. Make sure you are measuring the highlighted part and not the countersink.

Check the fit of the 6-32 Thread Size, 1/2" Long Bolt. For each of the 5 holes the bolt threads should go through the smaller hole and the head of the bolt should catch on the counterbore.
Check the fit of the 21700 cell in each of the cell holes. It should be a somewhat tight fit but the cell should be able to go in.
Check the fit of the M3 standoffs in the 5 standoff holes.

Items needed for tolerance check:

Check fit of Hex Socket Cap Screw M3 10mm in the 4 holes in the corner of the Bottom Bell Holder. They should be able to just fit through the hole.

Check the fit of the M3 standoffs in the 5 standoff holes.
Flip the cell holder over, check the fit of the 6-32 Thread Size, 1/2" Long Bolt. For each of the 5 holes the bolt threads should go through the smaller hole and the head of the bolt should catch on the counterbore.

Items needed for tolerance check:

Use calipers to check that the diameter of the 4 highlighted holes is 4 mm ±.5 mm.
Use calipers to check the diameter of the 4 highlighted holes 6.5 mm ±.5 mm.
Use calipers to check the diameter of the 4 highlighted holes 3.4 mm ±.5 mm.
Use calipers to check the diameter of the 2 highlighted holes 7 mm ±.5 mm
Use the calipers to check the dimensions of the highlighted rectangles 10mm by 3mm ±.5 mm.
Use the calipers to measure the diameter of the highlighted module-to-module connections, the diameter should be 12 mm ±1 mm. Make sure to measure the highlighted part and not the countersink.