18650 Battery Frame

All this started out as a question that was posted on the EndlessSphere E-Bike forum regarding the practicality of printing modules on on a 3D printer that could be assembled together to form a battery frame for an 18650 battery pack. I tried a small hex unit for a single 18650 cell with dovetails and came to the conclusion that it was more trouble than it was worth. Thus I decided to try larger modules.

Most e-bike batteries are in the range of 36 to 60 volts which is 10 to 15 cells in series. They are also commonly 4 or 5 cells in parallel. The largest section size that I can print on my Creality Ender-2 is 5 by 5 and I have to lie to Cura a bit to accomplish that. The Ender-2 has a bit larger print bed than some other 3D printers in the same price and size range. Thus I decided to create the modules in both four and five parallel sections. A 36 volt battery only requires two FourByFive or FiveByFive sections to assemble a frame for each side of the battery pack. For more cells in