I designed a case for the battery holder to sit in, with the cells parallel to the bottom of the case and a lid that slides over it. This leaves enough room for the BMS and the XT60 connector on top of the battery pack.
There are two holes for M2 heat-set nuts to be sunk in for the Amass XT60E-F connector I used. Two M2 hex-head bolts with washers secure the XT60. I also designed a clip to provide additional reinforcement for the XT60. It locks into the ridge of the connector and presses against the case.
This is the BMS that I used: https://www.amazon.com/dp/B07JMY631D
This is the XT60 Connector that I used: https://www.amazon.com/Amass-6Pairs-Connector-XT60E-F-Multicopter/dp/B0CFL3YSZS/ (You can find them cheaper on AliExpress, also I have no idea what size those screws are, they might not be M2)
I'm making use of cells recovered from a faulty Ryobi 40V battery. During cell sorting and testing I found that they averaged about 3900mAh so I'm expecting to see 11.7 Ah or about 140Wh (125Wh useable between BMS limits) out of this pack. It will mostly be used for extending my HF radio battery but it could be adapted to charge phones, laptops, whatever really.
Printed in PLA+ on an Ender 3 with a .6mm nozzle
3 Walls
25% infill (not that it really matters, its almost all walls)
I will probably add more to this and reprint in PETG. Let me know if I missed anything or if you have any questions.
The author remixed this model.
My version of the battery holder has 10mm gaps for 8mm nickle strips. I also designed a case and lid around this battery pack with room for a BMS and XT60 Connector.