The New Hotness

The Sony HDR-AS30V “action camera” uses NP-BX1 lithium batteries (3.7 V @ 1.24 A·h = 4.6 W·h) that are, of course, a completely different size and shape than any other lithium battery on the planet.

So.

Tweaking a few dimensions in the Canon NB-6L source code, tinkering with the layout of the contact pins, and shazam Yet Another 3D Printed Battery Test Fixture:

It builds nicely, although the contact pin tunnels are a bit too close to the top of the case:

After reaming out the contact pin holes to the proper diameters & depths, then gluing the plugs in place, it works just as you’d expect:

It’s worth noting that the Wasabi charger accepts the batteries upside-down, with the conspicuous chevron against the charger body. It’s definitely not the way all the other chargers work. The keying recesses on the battery (corresponding to the blocks in the solid model) lie along the bottom edge of the contact surface, so flipping the battery over means they’ll hold it in place, but … oh, well.

That grotty Powerpole connector last saw use in some random benchtop lashup. At some point I’ll be forced to start making more of those.

The OpenSCAD source code:

// Holder for Sony NP-BX1 Li-Ion battery
// Ed Nisley KE4ZNU January 2013

include <MCAD/boxes.scad>

// Layout options

Layout = "Show";					//  Show Build Fit Case Lid Pins Plugs AlignPins

//- Extrusion parameters - must match reality!
//  Print with +2 shells and 3 solid layers

ThreadThick = 0.20;
ThreadWidth = 0.40;

HoleWindage = 0.2;

function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

Protrusion = 0.1;			// make holes end cleanly

inch = 25.4;

BuildOffset = 3.0;			// clearance for build layout

Gap = 8.0;					// separation for Fit parts

//- Battery dimensions - rationalized from several samples
//  Coordinate origin at battery corner by contact plates on bottom surface

BatteryLength = 43.0;
BatteryWidth = 30.0;
BatteryThick =  9.5;

ContactWidth = 2.90;
ContactLength = 4.30;
ContactRecess = 0.90;

ContactOC = 10.0;			// center-to-center across contact face
ContactOffset = 6.20;		// offset from battery edge
ContactHeight = 6.30;		// offset from battery bottom plane

AlignThick = 2.75;			// alignment recesses on contact face
AlignDepth = 1.70;			// into face
AlignWidth1 = 3.70;			// across face at contacts
AlignWidth2 = 3.60;			//  ... other edge

//- Pin dimensions

PinTipDia = 1.6;
PinTipLength = 10.0;

PinTaperLength = 2.3;

PinShaftDia = 2.4;
PinShaftLength = 6.8;

PinFerruleDia = 3.1;
PinFerruleLength = 2.0;

PinLength = PinTipLength + PinTaperLength + PinShaftLength + PinFerruleLength;

ExtendRelax = 1.5 + ContactRecess;		// pin extension when no battery is present
ExtendOvertravel = 1.0;					//  ... beyond engaged position

//- Spring dimensions

SpringDia = 3.1;						// coil OD
SpringMax = 9.3;
SpringLength = SpringMax - 0.5;			// slightly compressed
SpringMin = 4.5;

SpringPlugOD = IntegerMultiple(5.0,ThreadWidth);		// plug retaining the spring
SpringPlugID = 2.0;
SpringPlugLength = IntegerMultiple(4.0,ThreadWidth);
SpringPlugSides = 3*4;

SpringTravel = ExtendRelax + ExtendOvertravel;

//- Holder dimensions

GuideRadius = ThreadWidth;			// friction fit ridges
GuideOffset = 7;					// from compartment corners
WallThick = 4*ThreadWidth;			// holder sidewalls

BaseThick = 6*ThreadThick;			// bottom of holder to bottom of battery
TopThick = 6*ThreadThick;			// top of battery to top of holder

ThumbRadius = 10.0;			// thumb opening at end of battery

CornerRadius = 3*ThreadThick;			// nice corner rounding

CaseLength = SpringPlugLength + SpringLength + PinLength - ExtendRelax
			+ BatteryLength + GuideRadius + WallThick;
CaseWidth = 2*WallThick + 2*GuideRadius + BatteryWidth;
CaseThick = BaseThick + BatteryThick + TopThick;

AlignPinOD = 1.75;			// lid alignment pins - filament snippets
AlignPinLength = 5.0;
AlignPinInset = 7.0;
AlignPinOffset = -3.75;		//  from centerline - choose to miss contact pins

//- XY origin at front left battery corner, Z on platform below that

CaseLengthOffset = -(SpringPlugLength + SpringLength + PinLength - ExtendRelax);
CaseWidthOffset = -(WallThick + GuideRadius);
CaseThickOffset = BaseThick;

LidLength = ExtendRelax - CaseLengthOffset;

echo(str("Contact pin tip dia: ",PinTipDia));
echo(str("Drill depth to taper end: ",
		 (SpringPlugLength + SpringLength + PinFerruleLength + PinShaftLength + PinTaperLength),
		 " -- Dia: ",PinShaftDia));
echo(str("            to ferrule end: ",
		  (SpringPlugLength + SpringLength + PinFerruleLength),
		 " -- Dia: ",PinFerruleDia));
echo(str("            to plug end: ",SpringPlugLength,
		 " -- Dia: ",SpringPlugOD));

//----------------------
// Useful routines

module PolyCyl(Dia,Height,ForceSides=0) {			// based on nophead's polyholes

  Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);

  FixDia = Dia / cos(180/Sides);

  cylinder(r=(FixDia + HoleWindage)/2,
           h=Height,
	   $fn=Sides);
}

module ShowPegGrid(Space = 10.0,Size = 1.0) {

  Range = floor(50 / Space);

	for (x=[-Range:Range])
	  for (y=[-Range:Range])
		translate([x*Space,y*Space,Size/2])
		  %cube(Size,center=true);

}

//-------------------

//-- Guides for tighter friction fit

module Guides() {
  	  translate([GuideOffset,-GuideRadius,CaseThickOffset])
		PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
	  translate([GuideOffset,(BatteryWidth + GuideRadius),CaseThickOffset])
		PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
	  translate([(BatteryLength - GuideOffset),-GuideRadius,CaseThickOffset])
		PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
	  translate([(BatteryLength - GuideOffset),(BatteryWidth + GuideRadius),CaseThickOffset])
		PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
	  translate([(BatteryLength + GuideRadius),GuideOffset/2,CaseThickOffset])
		PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
	  translate([(BatteryLength + GuideRadius),(BatteryWidth - GuideOffset/2),CaseThickOffset])
		PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);

}

//-- Contact pins (holes therefore)

module PinShape() {

  union() {
	cylinder(r=(PinTipDia + HoleWindage)/2,h=(PinTipLength + Protrusion),$fn=6);

	translate([0,0,PinTipLength])
	  cylinder(r=(PinShaftDia + HoleWindage)/2,
			   h=(PinTaperLength + PinShaftLength + Protrusion),$fn=6);

	translate([0,0,(PinLength - PinFerruleLength)])
	  cylinder(r=(PinFerruleDia + HoleWindage)/2,
				h=(PinFerruleLength + Protrusion),$fn=6);

	translate([0,0,(PinLength)])
	  cylinder(r=(SpringDia + HoleWindage)/2,
				h=(SpringLength + Protrusion),$fn=6);

	translate([0,0,(PinLength + SpringLength - HoleWindage)])	// windage for hole length
	  cylinder(r=(SpringPlugOD + HoleWindage)/2,h=3*SpringPlugLength,$fn=SpringPlugSides);

//	  translate([0,0,(PinLength + SpringLength + SpringPlugLength)])
//	  cylinder(r=(SpringPlugOD + HoleWindage)/2,h=2*SpringPlugLength,$fn=SpringPlugSides);	// extend hole
  }

}

module PinAssembly() {

  translate([ExtendRelax,ContactOffset,CaseThickOffset + ContactHeight]) {
	rotate([0,270,0]) {
	  PinShape();												// pins
	  translate([0,(1*ContactOC),0])
		PinShape();
	}
  }

}

//-- Alignment pins

module AlignPins() {

	for (x=[-1,1])
		translate([x*(LidLength - 2*AlignPinInset)/2,AlignPinOffset,0])
			rotate(45)
			PolyCyl(AlignPinOD,AlignPinLength);
}

//-- Case with origin at battery corner

module Case() {

  difference() {

	union() {

	  difference() {
		translate([(CaseLength/2 + CaseLengthOffset),
				  (CaseWidth/2 + CaseWidthOffset),
				  (CaseThick/2)])
		  roundedBox([CaseLength,CaseWidth,CaseThick],CornerRadius); 	// basic case shape

		translate([-ExtendOvertravel,-GuideRadius,CaseThickOffset])
		  cube([(BatteryLength + GuideRadius + ExtendOvertravel),
				(BatteryWidth + 2* GuideRadius),
				(BatteryThick + Protrusion)]);						// battery space

	  }

	  Guides();

	  translate([-ExtendOvertravel,-GuideRadius,BaseThick])
		cube([(AlignDepth + ExtendOvertravel),
			  (AlignWidth1 + GuideRadius),
			  AlignThick]);											// alignment blocks
	  translate([-ExtendOvertravel,
				 (BatteryWidth - AlignWidth2),
				 BaseThick])
		cube([(AlignDepth + ExtendOvertravel),
			  (AlignWidth2 + GuideRadius),
			  AlignThick]);

	}

	translate([(-ExtendOvertravel),
			   (CaseWidthOffset - Protrusion),
			   (CaseThickOffset + BatteryThick)])
	  cube([CaseLength,
		    (CaseWidth + 2*Protrusion),
		    (TopThick + Protrusion)]);								// battery access

	translate([(CaseLengthOffset - Protrusion),
			   (CaseWidthOffset - Protrusion),
			   (CaseThickOffset + BatteryThick)])
	  cube([(CaseLength + 2*Protrusion),
		    (CaseWidth + 2*Protrusion),
		    (TopThick + Protrusion)]);								// battery insertion allowance

	translate([(BatteryLength - Protrusion),
			    (CaseWidth/2 + CaseWidthOffset),
			    (CaseThickOffset + ThumbRadius)])
	  rotate([90,0,0])
		rotate([0,90,0])
		  cylinder(r=ThumbRadius,
				   h=(WallThick + GuideRadius + 2*Protrusion),
				   $fn=22);											// remove thumb notch

	PinAssembly();

	translate([-LidLength/2,BatteryWidth/2,CaseThick - TopThick - (AlignPinLength - TopThick/2)])
		AlignPins();
  }

}

module Lid() {

  difference() {
	translate([0,0,(CaseThick/2 - BaseThick - BatteryThick)])
	  roundedBox([LidLength,
				 CaseWidth,CaseThick],CornerRadius);

	translate([0,0,-(CaseThick/2)])
	  cube([(LidLength + 2*Protrusion),
		    (CaseWidth + 2*Protrusion),
		    (CaseThick)],center=true);

	translate([-ExtendRelax,0,-(AlignPinLength - TopThick/2)])
		AlignPins();
  }

}

module PlugShape() {

  difference() {
	cylinder(r=SpringPlugOD/2,h=SpringPlugLength,$fn=SpringPlugSides);
	translate([0,0,-Protrusion])
	  PolyCyl(SpringPlugID,(SpringPlugLength + 2*Protrusion),SpringPlugSides);
  }
}

module Plugs() {
  translate([0,ContactOC,0])
	PlugShape();
  translate([0,-ContactOC,0])
	PlugShape();
}

//-------------------
// Build it!

ShowPegGrid();

if (Layout == "Case")
  Case();

if (Layout == "Lid")
  Lid();

if (Layout == "Plugs")
	for (i=[-1:1])
		translate([i*1.5*SpringPlugOD,0,0])
			Plugs();

if (Layout == "Pins")
  PinShape();

if (Layout == "AlignPins")
  AlignPins();

if (Layout == "Show") {								// reveal pin assembly
  difference() {
	Case();

	translate([(CaseLengthOffset - Protrusion),
			   (CaseWidthOffset - Protrusion + WallThick + ContactOffset + ContactOC),
			   (BaseThick + ContactHeight)])
	  cube([(-CaseLengthOffset + Protrusion),
			 (CaseWidth + 2*Protrusion),
			 CaseThick + BaseThick - ContactHeight + Protrusion]);

	translate([(CaseLengthOffset - Protrusion),
			   (CaseWidthOffset - Protrusion),
			   -Protrusion])
	  cube([(-CaseLengthOffset + Protrusion),
			 (WallThick + GuideRadius + ContactOffset + Protrusion),
			 CaseThick]);
  }

  translate([ExtendRelax,ContactOffset,(CaseThickOffset + ContactHeight)]) {	// pins
	rotate([0,270,0]) {
	  %PinShape();
//	  translate([0,(2*ContactOC),0])
//		%PinShape();
	}
  }

  translate([CaseLengthOffset,ContactOffset,(CaseThickOffset + ContactHeight)])
	rotate([0,90,0])
	  PlugShape();
}

if (Layout == "Build") {
  translate([-(CaseLength/2 + CaseLengthOffset),-(CaseWidthOffset - BuildOffset),0])
	Case();
  translate([CaseWidth/2,(CaseLengthOffset/2 - BuildOffset),0])
	rotate([0,0,90])
	  Lid();
  for (i=[-1:1])
	translate([CaseLengthOffset/2 + i*1.5*SpringPlugOD,-CaseWidth/2,0])
		Plugs();
}

if (Layout == "Fit") {
  Case();
  translate([(-LidLength/2 + ExtendRelax),
			(CaseWidth/2 + CaseWidthOffset),
			(BaseThick + BatteryThick + Gap)])
	  Lid();
  translate([ExtendRelax,ContactOffset,CaseThickOffset + ContactHeight]) {	// pins
	rotate([0,270,0]) {
	  %PinShape();
	  translate([0,(1*ContactOC),0])
		%PinShape();
	}
  }

  translate([CaseLengthOffset,
			(ContactOffset + ContactOC),
			(CaseThickOffset + ContactHeight)])
  rotate([0,90,0])
	Plugs();

  translate([-LidLength/2,BatteryWidth/2,CaseThick])
#	AlignPins();

}