Articles & Resources

Can You Use PLA for 3D-Printed Battery Frames?

PLA starts to soften around 60°C, but that does not automatically make it unusable for battery frames. In many well-designed packs, the welded cells, enclosure, and overall fitment provide the rigidity, making PLA a workable option even if PETG or higher-temp materials are better choices.

Why Use Insulator Discs?

The only thing separating those things, if you do not use insulator discs, is just microns of cell wrap. Some people will point out that lithium-ion battery cells have insulator discs built in. But if you take apart just about any lithium-ion battery cell, you will see that the built-in white plastic insulator disc does not fully cover the negative, because it is slightly undersized for the cell.

How To Build A Spot Welder From Scratch - Part 1: Theory And Architecture

Well, a spot welder is just a massive switch. When I say massive, I mean electrically massive, meaning it can handle thousands of amps for a small period of time. It is a massive fast switch. A switch so electrically massive and so stunningly fast that it makes even the fastest highest-current relays look like child’s playthings.

How To Estimate A Current Rating Using Resistance

By comparing real datasheets, we can see that a continuous heat dissipation of about 0.35 watts per cubic centimeter is a common, conservative limit that aligns well with how cells are actually rated. Using this value, we first calculate how many total watts of heat a cell of a given size can safely dissipate, then use the cell’s measured internal resistance to calculate the maximum continuous current that would produce that amount of heat. The result isn’t a perfect or guaranteed rating—but it’s far more grounded in physics and real-world data than guessing, marketing claims, or assuming ideal conditions.

Is Cell Level Fusing Required For A Safe Battery?

Let’s take some time to look at the protection mechanisms that are built into just about any quality lithium-ion cell. The phrase “just about any” is important, because there are some very poor cell manufacturers in the market. However, any manufacturer worth their weight in lithium implements all of the mechanisms discussed below.

Best Battery for High-Powered Flash Lights

Is a higher mAh rating always better? Not necessarily. When it comes to high-power LEDs, internal resistance can be the difference between a bright beam and a battery that overheats. We do the math on 1,000 vs. 3,000-lumen lights to show you exactly when to prioritize capacity and when to hunt for low-resistance "power" cells.

FAQ: Charging & Safety for Lithium Batteries

Charging a lithium battery with the wrong charger can lead to fire or explosion. This guide covers the essential "Do's and Don'ts" of lithium-ion and LiPo batteries, explaining the role of a BMS, the 80% rule for longevity, and safe storage practices to keep your home and devices protected.

FAQ: Lithium Battery Basics

While 'lithium' and 'lithium-ion' are often used interchangeably, using the wrong charger or assuming they are the same can be a costly mistake. This guide breaks down the technical differences between primary lithium cells and rechargeable Li-ion families like LiPo and LiFePO4. Whether you're looking for voltage patterns or trying to tell an AGM battery apart from lithium, our FAQ has the answers you need to stay powered safely.

So, What Exactly Is A Resistor?

Think of a resistor like a narrow section of pipe—it makes it harder for the 'water' (current) to flow. But there is much more to this humble component than just simple obstruction. From protecting sensitive LEDs to setting precise voltages and dissipating heat, resistors are the unsung heroes of electronic design. Dive into our comprehensive guide to understand the physics of resistance, the impact of temperature, and the vital formulas every maker needs to know.