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Fake AA AAA battery for using a power supply design in openscad

by sigoestudiando Jan 8, 2015
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Thank You for this very fine design, it’s perfect for my purpose.
I just post my make,

This isn't mathing out. (AAA) The Printed shell is 43.5mm long with, Standard M2 head is 1.6mm tall (so saith McMaster-Carr) inset .3mm into the shell (so +1.3mm protruding positive terminal) and Standard M3 head is 2.4mm tall and is inset 1.7mm (so +.7mm protruding negative terminal).

That gives an overall assembled length of 45.5mm. The MAX length of a AAA battery is defined as 44.5mm (min 43.3mm). So that's 1mm to 2.2mm of allowable plastic shrinkage, but it would have to shrink at least that 1mm (2.3%)

To counter that the inset holes for the screws are already .2mm smaller that the heads of the screw (6mm⌀Head in 5.8mm⌀ & 4mm⌀Head in 3.8mm⌀), Required shrinkage would only make them even more undersized.

Also the Negative terminal must be 7mm⌀ Minimum but the M3 is only 6mm⌀, The Model should be reworked for at least a M3.5 (7mm⌀) or a 6-32

As an improvement, a Flat-head style screw would fit devices better than Pan-head when installed on the negative terminal, but this would require a 82° counter sink (angled) hole in the model. Like a M4 (flathead) or 8-32

I had been considering something like this so I could easily use a wall wart to supply power to all my kids' battery-powered toys. For toys requiring multiple batteries, you could print extra fake batteries and solder a wire to run from the top to bottom of each extra "battery" to complete the circuit.

Thank you for this!