Battery Connector for Milwaukee M18

DESCRIPTION

If you've ever wanted to make use of those Milwaukee M18 18V batteries, you are going to want a solid and clean way to get to the battery terminals. This 3D print provides a plastic plate assembly that slips onto the battery, snapping on just like a Milwaukee power tool.

The battery connector assembly consists of two components. The main component clamps to the Milwaukee battery. The second part performs the electrical connection to the battery.

The electrical terminals connections are reproduced using automotive 3mm red blade connectors. These connections are used without the red insulator (apply heat to soften the insulation for easy removal). The bare connection with a crimped or soldered to wire, then sandwiched between two parts that firmly secure the automotive connectors. The two printed parts sandwiching the connectors are held together by an M3 (3mm) x 8mm screw.

The black electrical part attaches to the red battery mount part with two parallel M3 (3mm) x 15~17mm screws. See included photos for assembly details.

I've included a hole mount overlay to assist makers to match the battery plate into their designs. See “Mounting Holes Overlay.jpg”.

I've also included the STEP CAD file to assist people to incorporate the model into their designs. If you're like me, it doesn't matter how much care you take, it's still possible to miss details in the 3D design. Typical missed details that will lead you into problems include:

• Parts encroaching on others.
• Hole spacings misaligned.

A 3D model of each component incorporated into your design helps avoid some of the design pitfalls.

THANK YOU

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PRINTING INFORMATION

My print is made in 1.75mm Bambu Lab eSUN PLA+ Red filament, with 0.2mm layer height on a Bambu Lab H2D printer.  Print supports are recommended as indicated in a photo. The electrical terminal parts are made in PETG 1.75mm filament.

Both print profile and the individual STL files are included for download.

HISTORY

26/01/2023

• File "Contact Plate - Bottom.stl" updated to accept screws with larger heads, up to 5.5mm.

25/03/2023

• Added a version with a thicker base plate that now aligns with top of the battery.
• Adapter plate has a sloped end aligning with the battery (cosmetic, see photos).

08/11/2023

• Updated “Battery Plate - Thick.stl” to ensure that a mount hole passes all the way through the part.