Spot weld helper

This OpenSCAD script generates a simple spot weld helper for battery cells. Depending on the desired number of cells and their dimensions it creates two matching holder objects.

One base object has cut-outs for the number of cells whereas the second object (slider) has two cut-outs on both sides. The second row is designed for one less cell so that battery packs with tightly packed cell can be easily created.

Both objects can have embedded magnets to hold the cells in place. They can either be embedded in the print or inserted into proper slots from the bottom.

The script includes variables for the OpenSCAD customizer to easily adapt it to different needs. A description of all variables is given below.

Customization

The script uses the customizer functions provided by OpenSCAD. There are four groups of settings that can be adjusted.

Cells

• Number of cells
  Define the maximum number of cells in a row.
• Cell diameter
  Nominal diameter of each cell in millimeters.
• Cell height
  Nominal cell height. Used to calculate the object height (cell height minus 5 mm).
• Cell spacing
  Distance between the cell you want to use (Cell diameter plus 0.2 mm usually works fine)

Magnets

• Use magnets
  Allows you to disable all magnet insert pockets.
• Integrate magnets
  Generates either open pockets or embedded pockets that require you to pause your print and insert the magnets. If your mangets have different heights you might needs two pauses when printing both objects at the same time.
• Magnet 1 width, height, depth
  The dimensions of the first magnet. Pockets will add a tolerance to these values.
• Manget 2 width, height, depth
  Magnet dimensions for the second object. Since this one has two rows of cell holders the magnets are placed in closer distance and need to be smaller.

General dimensions

• Use axis guides
  Creates the axis guides in both objects so that the second one can be easily moves in parallel to the first one.
• Axis diameter
  Diameter of the axes to be used, in millimeter.
• Base width
  Dimension for the support width on the first part, in millimeters.

Tolerances

• Tol
  Tolerance used for most cutouts (axes, magnets)
• Extrusion width
  On some features with thin walls the minimum wall thickness can be set to multiples of extrusion width. This is to ensure your slicer can properly slice the objects.
• Min wall lines
  This sets the mimimum wall thickness in multiples of extrustion width for thin walls, e.g. between the magnet and battery cell and the "tip" between the cell cutouts.
• Bevel Large
  Both objects are beveled at certain edges. This is the larger bevel size in millimeters.
• Bevel Small
  Both objects are beveled at certain edges. This is the small bevel size in millimeters.