I was originally thinking of 3d printing them in sections and join them together if the printer is not capable of printing the whole thing in a single shot.
Actually, I'm totally new to 3d printing but familiar with Solidworks (works related). I like to design and some were turn-key projects from concepts to complete functional ones - everything in between - and rather the whole system than individual device or part. I haven't owned a 3d printer yet, but considering one. Aiming towards Creality CR-10s (or the clone "Anet e12" around US$5xx.- local, with all the overhead) for its bigger printable size. Prusa i3 mk3 is a bit small and rather pricey in my area after all the mark-ups, tax, shipping, 2 free spools and etc.(almost US$1500.- crazy!!). That's why we are so left behind.
Any sweet model ?
That sounds good, spinningmagnets. Thanks for the tips - I will have to seriously give it a deep analysis.
Currently, I'm thinking of vacuum forming (to get it in one nice solid piece) the main battery compartment out of polycarbonate or ABS due to their durability & ease. Breaker, fan, charging/discharging, USB ports, key are to be directly mounted within this box to be fully functional. Later we can add the 3d-printed detachable facades (L & R) to make it handsome. Imagination to be refined. Again, this is from pure desire for design and DIY.
All this batt case builds is to be a real power pack for my MTB to climb a high mountain mission, with 50+km range and 3,000+m in elevation. Plus, the mission will inspire local people that real ebike can be their main method of transport besides the recreation it brings. I mentioned here in ES that real ebikes are hard to find where I live. Some of those 200-300w front hub can be occasionally spotted. So, I first DIY it with BBSHD kit with fun in mind. Now people start showing interests and asking about how this and that more oftenly.
Still, the cells are to be welded. 14S7P & 14S5P (or14s4p) Have not ordered anything yet. Quite some works.
Off topic question :
Is it a good idea to parallel ;
(A) Triangle 14s7p (98 pcs of LG MJ1 - @3.4Ah/10A max)
(B) Tube 14s5p (or 14s4p) (70 or 56 pcs of LG HG2 - @2.9Ah/20A max)
for climbing high mountain. Or should they be the same type ?
In daily uses, only one pack will be needed.
Ha Ha, So I will end up building everything on my own. May be the tiny motor with super energy density, gyro-controlled bike that never tips over, shaft-driven bike, etc.
I have to seriously take a look into that, Sir.
Thanks a bunch for all the comments here. I learned a lot in ES with the helps, encouragement and inspiration from you guys.
Truly appreciate it.
P.S. the very 1st crude draft I sent to a polycarbonate forming shop for quote today :