Dewalt Tool Battery Starlink Mini Slim Adapter - Free 3D Print Model

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Digg

Hobby & DIY>Electronics

IP Report

Print Profile(2)

All

P1S

P1P

X1 Carbon

X1E

A1 mini

H2D

H2D Pro

H2S

P2S

H2C

X2D

A2L

0.2mm layer, 6 walls, 25% infill

Designer

4.8 h

2 plates

5.0(15)

0.2mm layer, 6 walls, 25% infill

5.2 h

1 plate

5.0(3)

Open in Bambu Studio

Boost

738

1777

757

366

Released

Description

This model allows you to use Dewalt 20v batteries with the Starlink Mini. Key features include a simple click in/click out design, low voltage disconnect, and a slim design that does not add any thickness to the dish when installed. The adapter clicks into the back of the dish and automatically connects into the existing power port on the back of the Starlink. Additionally, the design incorporates a low voltage cutoff to prevent over discharging the batteries. I printed this design using PETG-HF, but would imagine PLA and ABS would work great as well.

My limited endurance testing has showed about 1.5 hours with the smaller 2Ah 20v battery and about 4 hours with the 5ah battery.

Bill of Materials:

1x Rocker Switch (Amazon Link)
1x DC Low Voltage Disconnect Board (Amazon Link)
1x 2.1mmx5.5mm Male Barrel Plug connector (Amazon Link)
2x Blue Male Spade Connector
8x M3 Threaded Insert (Amazon Link)
4x M3x4mm (to hold PCB board down)
4x M3x8mm (to hold battery top plate down)
4x M3x10mm (to attach to the two halves)

Assembly:

Install the 8x M3 threaded inserts into the prints using a soldering iron. 4 on the bottom plate (pictured) and 4x on the top plate (not pictured)
In order for the PCB to fit, de-solder and remove the green connectors from the PCB. Install into the print with 4x M3x4mm screws. These screws thread into the print itself without threaded inserts. Do not over tighten.

Remove the casing from the butt connectors. These will serve as the contacts for the Dewalt battery.
Install the switch into the top plate and wire up as in the following photos. The plug sits into the fitting a pictured. It is sandwiched between the top and bottom parts of the print. I intentionally leave it slightly loose as to not damage to the Starlink dish when inserting and removing this adapter.
Glue the “clips” into the bottom of the adapter. I prefer to put the slanted side toward the back of the adapter to make removal from the dish easier. I use CA super glue to install the clips.
You can use an allen key or screw driver to press the buttons on the PCB to adjust the voltage cut-off voltage. I set mine to 16.5 volts.

Comment & Rating (79)

@EzJ3dPrints

no need to desolder the green connectors, just route the cables properly and and zip tie them.

(Edited)

The designer has replied

@Digg

Good find, i thought they were too tall for the top piece to fit on flush with the green connectors installed. Maybe an oversight on my part.

@Stephenle504

I would love this for an m18 battery.

@MattMo15

same here!

@stasnami

same!

@ByteSizeNinja

100% need a remix of this with m18 batteries

@user_2064145511

I was thinking of designing something like this until I came across this awesome design. I’m sure it took lots of hard effort and saved me some time also. I printed this in ABS for outside heat and UV durability. I used a few drops of acetone to secure the bottom clips since they’re also ABS. I set the battery spade terminals and output plug with hot glue. Luckily, I already had all of the parts because I’ve designed similar Dewalt adapters with a voltage cutoff board for other projects. I set cutoff to 16.0V and restart differential to 1.0V. Nice job! Thanks for sharing!

(Edited)

@Cinemaan

Boosted

Print Profile

0.2mm layer, 6 walls, 25% infill

Absolutely amazing file. What a fun project! Everything went together beautifully! A plug/cap for the display opening would be my only change, then I could RTV and seal everything else and make it waterproof. Couldn't find m3x4mm screws locally for the board, used m3x6mm instead and printed 2mm spacers to make up the difference. Also tidied up the wires and routed them a little differently as not to cross over the board. Hot glue all wires in place to mitigate vibration damage. THANK YOU!!!

@Douggle

Boosted

One of the most satisfying prints I’ve done! I only needed the screws and the voltage cutoff board. Thank you for the links! I’d love to make a modified version with USB power and a doc for the Unifi travel router!

@user_1897542003

Should the inclined surface be adhered in the direction indicated by the red arrow in the picture?

The designer has replied

@Digg

I found it doesn't really matter. Technically the inclined surface should allow it slide in easy, but have to be "bent" to take out, but in reality i've installed them both ways with minimal difference in use.

@GVIIDriver

I couldn’t be happier for this. I built mine for the Milwaukee battery. I have tried several different battery solutions for the Starlink but nothing comes close to this. THANK YOU!

@chronoflux

Print Profile

0.2mm layer, 6 walls, 25% infill

perfect print. looks so clean and everything fits like a glove. great work!

(Edited)

@Printovate

this turned out pretty rad! thanks for posting! Bambu PETG Translucent Gray

@epetrushak

Boosted

Print Profile

0.2mm layer, 6 walls, 25% infill

I'm glad I came across this model! I've had my Starlink Mini for over a year now and had seen a lot of posts about people that had these setups. I finally have one of my own now! This was very easy to print (I printed mine in ABS) and assemble. The guide and the pictures made it quite easy. Thank you!