I bought a spare battery for my phone. It is great having the ability to swap batteries.
Unfortunately, I can't recharge a dead battery when using a fresh one. So, I decide to make a battery charger.
In this build, I elected to use pogo pins for battery contacts. Pogo pins are spring loaded contacts used in circuit board test jigs. They are similar to watch band pins. I used pogo pins because the Samsung battery contacts are very unique.
- 3D printer (Printrbot Simple Metal)
- 4-40 Tap
- Rotary Tool
- Digital Caliper
- Autodesk Fusion 360 or equivalent
Step 1: Measure
Before designing in CAD you need to take measurements.
Of everything. Needless to say, take measurements of the overall battery. Then take precise measurements of the battery contacts. Note the centerpoints of the positive and negative contacts.
You can get the dimensions of the LiPo charger module from the Adafruit site.
Step 2: Design
Autodesk Fusion 360 was used for this design. Other CAD software could be used since the shape is simple.
The design is straight forward. The charger module is located at the top. Channels were created for the wire. The pogo pins were 1mm in diameter. The channels were the same 1mm width for a tight fit.
The 3d printer file (.stl) is attached.
Step 3: 3D Print
My first attempt didn't work so well.
The printed part was at the limit of my printer capabilities.
I ended up having to print it diagonally...a few times.
Print resolution 0.2 layer height, Hot end temp: 205. Bed temp: 70 Generic PLA.
Step 4: Make the Cover
Use 1/8" clear sheet acrylic for the cover.
Clear was used to see the different color states of the battery charger.
Simply mark the locations for the mounting holes.
Drill and cut the cover with a rotary tool.
Step 5: Final Assembly
Solder the pogo pins to the charger wires.
Use the 4-40 tap to thread holes for the acrylic cover.
Mount the board and acrylic cover.
Apply the label (see the pdf uploaded file.)
Lithuim batteries are potentially dangerous. Test the build by closely watching it during the first usage. Just in case, isolate the charger from flammable materials when first testing. Once everything checks out, pat yourself on the back for another successful build! :)
Thanks for viewing my Instructable.
Participated in the
Design Now: 3D Design Contest 2016