Design Overview

Aim
To design a durable and functional case to securely hold and protect a 17 Ah battery within the frame of a full-suspension e-bike.

Key Requirements

• Secure: The case must securely hold the battery, making it difficult for thieves to remove.
• Precise Fit: Designed to fit the battery and bike frame with minimal free play to prevent movement.
• Functional: Incorporate provisions for the power lead, charging port, and power switch for seamless operation.

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Design Details

1. CAD Modelling
   • CAD models of the battery and relevant sections of the bike frame were created to establish the foundation for the case design.
   • These models ensured a precise fit while optimizing space within the bike frame.
2. Iterative Feature Development
   • The fundamental shape was refined to include features for functionality, including:
     • Ports for power leads.
     • Accessible charging port.
     • A built-in recess for the power switch.
3. Modular Construction
   • Due to the case’s size, it was designed in seven primary sections, each small enough to print on my 3D printer.
   • The sections were designed to bolt together seamlessly, ensuring structural integrity while maintaining portability.
4. Waterproofing Measures
   • Joint areas included gaskets to minimize water ingress, originally printed in TPU.
   • After testing, a silicone sealant was found to be more effective, providing superior waterproofing and durability.

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Results

The final battery case successfully meets all design objectives:

• Security: The modular bolted construction ensures the battery is held firmly and resists tampering or theft.
• Precision: The tight tolerances in the CAD design result in a snug fit with minimal movement.
• Functionality: Integrated features for the power lead, charging port, and switch ensure the battery is easy to use without compromising protection.
• Durability: The use of silicone sealant for waterproofing enhances the case’s resilience against weather conditions, ensuring reliable performance over time.

This design offers a practical and innovative solution for integrating a large battery into a full-suspension e-bike while prioritizing security and functionality.