Battery Design & Assembly

3D Printing for Battery Packs: Materials, Design, and Safety

A custom 3D printed enclosure separates a pro DIY build from a bundle of tape. But choose the wrong filament, and your battery case will warp, crack, or melt in your car. In this material science guide, we evaluate PLA, PETG, ABS, and Nylon for battery applications and discuss critical design rules for structural integrity.

02 Oct 2025 Read More

Battery Design & Assembly

Battery Connector Guide: XT60, XT90, and Anderson

You can build a battery capable of dumping 200 Amps, but if you push that through a fake XT60 connector, you are building a fuse, not a power system. In this electromechanical analysis, we compare the contact resistance, thermal limits, and spark-suppression features of the industry's most popular plugs to help you stop melting your terminals.

30 Sep 2025 Read More

Battery Design & Assembly

Compression Methods for LiFePO4 Prismatic Cells

If you read the manufacturer datasheet for EVE or CATL cells, you will see a requirement for 300kgf of clamping force. Why? In this mechanical engineering guide, we explain why LiFePO4 cells expand when charged, how this destroys internal layers, and how to build a proper spring-loaded compression fixture to double your cycle life.

28 Sep 2025 Read More

Battery Design & Assembly

Wiring Guide: AWG Charts and Voltage Drop

A battery is only as powerful as the wire connecting it. Using the wrong gauge can turn your cables into heating elements, causing voltage sag and fire risks. In this electrical engineering guide, we dissect the difference between Silicone and PVC insulation, provide a definitive AWG ampacity chart for DC systems, and explain the physics of resistance in high-current interconnects.

26 Sep 2025 Read More

Battery Design & Assembly

Modular vs. Monolithic Pack Design

The instinct of every new builder is to spot weld all 100 cells into one massive monolithic block. In this architectural guide, we explain why building smaller 24V or 12V modules connected in series is safer, easier to repair, and the only way to future-proof your energy storage.

24 Sep 2025 Read More

Battery Design & Assembly

Insulation Guide: Fishpaper, Kapton, and Short Prevention

The most common cause of catastrophic battery fires isn't bad chemistry; it's bad insulation. In this safety deep dive, we explore the anatomy of the "Guillotine Short," why PVC shrink wrap is not enough, and the specific material properties of Vulcanized Fiber (Fishpaper) vs. Polyimide (Kapton) that save lives.

23 Sep 2025 Read More

Battery Design & Assembly

Cell Holders vs. Glue: Structural Assembly Methods

The debate between "Hot Glue" and "Plastic Holders" is one of the most contentious in the hobby. One is cheap and compact; the other is robust and safe. In this structural analysis, we compare the thermal properties, vibration resistance, and safety margins of both assembly methods to help you decide if saving 5mm of space is worth the risk.

21 Sep 2025 Read More

Battery Design & Assembly

Busbar Design for High Current Applications

When your e-bike or EV build exceeds 50 Amps, standard nickel strips become dangerous heating elements. To handle the power, you must switch to copper. In this advanced assembly guide, we teach you the physics of the "Copper-Nickel Sandwich," how to weld highly conductive metals, and how to size your busbars for 200A+ loads without melting your pack.

21 Sep 2025 Read More

Battery Design & Assembly

Spot Welding vs. Soldering Lithium Cells

Can I just solder my 18650s? This is the most common question from beginners, and the answer is a resounding NO. In this engineering analysis, we dissect the internal structure of a lithium cell to explain exactly why soldering heat destroys safety seals, degrades chemistry, and creates latent failure modes.

20 Sep 2025 Read More

Battery Design & Assembly

Nickel Strip Selection: Pure Nickel vs. Plated Steel

The single most common cause of battery fires in DIY packs is not the cell, but the interconnects. Nickel-plated steel strips have four times the resistance of pure nickel, turning your battery into a heater. In this materials science guide, we teach you how to spot fake nickel, calculate exact ampacity limits, and design current paths that run cool.

19 Sep 2025 Read More