Teasers of a battery I'm designing.

[Tom Cole]

The idea is to hold groups of 18650 batteries securely inside a tube with a little breathing room between the batteries allowing for wires and such.  This group of 8 will fit into a 2.5" OD piece of tubing.  This is only a prototype.

[Tom Cole]

Further prototypes. You can see how they will be wired together and how they fit into a 3"IPS PVC pipe.  The model on the right in the first 2 pics is an earlier prototype.  I am cutting away an area for the BMS as well as reducing the amount of plastic to reduce print time.  This battery will be a 10S4P setup using NCR18650GA cells yielding a 36V 14Ah battery with a 40A max continuous discharge rate.  Total length will be 33cm or a little longer than the length of 5 batteries.

I am designing this using Fusion 360, sending the .stl file to Slic3r 3D and printing on my Prusa i3 MK2 3D printer.

[Tom Cole]

Further model changes...getting closer!

[Tom Cole]

This project is done and available here for free: http://www.wattcycles.com/index.php?topic=90.0