Battery protection box for LiFePo batteries

All LiFePo batteries I own have a connection cable that comes out of the battery casing and ends in a pair of Powerpole connectors.

After prolonged use, the connection cable becomes increasingly “flexible,” meaning that more and more wires in the high-current strand break. As long as the break is close to the connector plug, this is not a problem and can be easily repaired. However, if the break is where the cable exits the battery casing, it becomes difficult to repair the damage.

Case

To get around this problem, I designed a simple housing in which the battery is inserted and the Powerpole connector is securely locked in place.

The device can then be reliably connected to the Powerpole connector.

The current version of the case also features nicely rounded edges and circumferential grooves, allowing the case to be securely closed.

Many thanks to DF5WC ‘Utz’ for revising the design with rounded edges.

For simplicity's sake, I sealed the two halves of the housing with adhesive tape. The two halves of the housing can, of course, be permanently sealed with superglue, for example.

Files

OpenSCAD Source (right-click + save file as ...)
STL-File

How to get a case

I designed the housing in OpenSCAD and then printed it on my 3D printer. It is very easy to design “customized” housings of almost any battery size. The corresponding comments are stored in the SCAD file.

First, however, an STL file must be created using OpenSCAD.

Measure your battery accurately.
Enter the dimensions in the SCAD file under the values batteryHeight, batteryWidth and batteryLength.
Generate the model using the F6 function key.
If it meets your expectations, you can use the F7 function key to generate an STL file.

This STL file can then be processed by most 3D printing providers.

There are many suppliers who can print the 3D housing. I cannot comment on the quality as I own a 3D printer myself.

Hint: If you live in the Stuttgart area, I may be able to print a case for you in return for reimbursement of my expenses.