Battery Module Manufacturing
- Micah Black
Owned by Micah Black
This page lists all the different materials required to manufacture the modules.
We will start with the calculations for how much material we need, then move on to where we will be acquiring the raw materials, and how they will be turned in to the functional parts. Manufacturing steps and processes will be listed as well.
Each line item should link to a sub-page with more details on that item.
| Material | Specifications | Amount Required | Source | Manufacturing Process | Manufacturing Location | Manufacturing Steps |
|---|---|---|---|---|---|---|
| Nickel Strips |
| 100m or 800g | In the bay | Bend with jig, cut with scissors | ||
| Module Busbars - EMS Sigma Clad 60 | Spec sheet in side | about 30 sq ft. | EMS | Water Jet Cutting | Water jet place / bay | Water jet, bend using a jig and vise. |
| Cell Holders - 3/8" Acetal Sheet | 3/8" Acetal (not Delrin) Black (not Natural color) | about 30 sq ft. | Piedmont Plastics | CNC | E5 Machine Ship /bay | CNC, manual deburr, manual fillet |
| Fish Paper | Adhesive backed | 145P Tags | Laser cutting (with Micah's laser cutter?) | Outside | Cut it and stick it on. | |
| Aluminum Standoffs | M3, F-F, 60mm | 140 | Aliexpress | None | None | None |
| Heat Set Inserts, M3 | Tapered, M3, long | McMaster / Spaenaur | Soldering iron installation | Bay | Press in with DIY soldering iron press. Press is complete. https://hackaday.com/2019/02/28/threading-3d-printed-parts-how-to-use-heat-set-inserts/ | |
| Gusset Plates | Custom Design Captive Nuts | 80pcs, 40 of each | Filament from 3D Printing Canada | 3D Printed | Bay | Print them out, usual print post-processing |
| Top Hard Insulation Cover | Probably Acetal, maybe acrylic 3/64" thick | McMaster | Laser Cut | WatiMake (Thanks Tommy!) | Laser Cut it | |
| Series Connection Hardware |
| McMaster / Spaenaur | Bay | Manual Assembly | ||
| PCB Mount Hardware |
| McMaster / Spaenaur 3D Printed | 3D Printing, Manual Assembly | Bay | Put it together | |
| Balance Wiring |
| Digikey / IEWC | Bay | Manual Crimping | ||
| Thermistor Assemblies |
| Digikey | Bay | Manual Assembly | ||
|