#0047 [Improved] AAA and AA Battery Dispenser [FIFO]

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[UPDATED Dec 21, 2023]  updated the battery removal area as @Runboy suggested, so now there are two methods for removing the batteries.  I can't believe I didn't think of that myself! ;-p

Updated Jan 2, 2023:  Improved the battery removal area to make it much easier to remove batteries. New .3mf and .stl files have replaced the previous ones.

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I use rechargeable batteries almost exclusively and wanted a battery holder that can hold at least 18 batteries each of the AAA and AA battery sizes and provide first-in first-out access. After searching through various sites for something to print, I found that my choices were very limited, mostly they didn't hold enough batteries or they looked very utilitarian.  I finally decided that I wanted to design my own.  

But after playing with some initial designs, I couldn't come up with one that satisfied my own requirements, which were: 

1. Large enough to fit at least 18 batteries of each size --AAA and AA
2. FIFO: Provides “first-in first-out” access to batteries
3. Prints in one piece without supports
4. Fits my Prusa MK3S+ printer bed
5. Functional but can be interesting to look at

Then came the inspiration: come up with a “sculpture” that also functions as a battery holder – "functional art".  The 2 “legs” are connected for stability, but I made them appear separate.

1. The AAA leg fits 25 batteries.
2. The AA leg fits 19 batteries.

The Supplies I Used:

The co-extruded filaments I used can be found here: 

Tri-color PLA, Red-Yellow-Blue: https://amzn.to/41PnN9U

Dual-color PLA, Silver-Blue: https://amzn.to/3IVkpSv

My favorite rechargeable batteries are Eneloops and can be found here: 

AA, 4 pack: https://amzn.to/3IVkpSv

AA, 12 pack: https://amzn.to/3ye4hGK

AAA, 8 pack: https://amzn.to/41SjFGo

AAA, 12 pack: https://amzn.to/423vp9d

Why does FIFO Matter?

Rechargeable batteries have limited shelf life because they “self discharge” on the shelf waiting to be used.  Mainly for that reason, you would want to use the ones that have been “in the queue” first so you don't lose track of which is which.  FIFO ensures that you honor the queue and use the oldest ones first.

I use Panasonic Eneloops which are great for having low self-discharge rates, but they still do lose some charge waiting to be used. (This concept applies to non-rechargeable batteries as well.)

This is my first attempt at “functional art”, and I think it checks all the boxes I listed above.  The organic shape hints at “plants”, “fire”, or “steam” depending on who's looking at it and which colors you choose to print in.  It works pretty well too, but make sure you confirm the following before you spend the time and commit the filament to print it:

1. PLA recommended - perfect use of this material. 
2. Your printer settings can handle bridging well.  The bridging forms a wall that is important for the battery dispenser to work smoothly. Poor bridging may cause the batteries to “catch” inside the dispenser.
3. Good bed adhesion is critical because this part takes up most of the diagonal of the print bed.  Make sure you print with a clean print bed to avoid lifting/warping. I added an adhesion helper disc in one of the ends in my .3mf file that has worked well for me on multiple prints.
4. Use a 3-4mm brim if you are not confident in your bed adhesion.
5. Make sure (watch) that the first layer is successful.
6. Seams: aligned
7. Infill: at least 15% gyroid recommended.

Removing Batteries:

The “wall” is there to prevent the battery from sliding out accidentally when you are handling the sculpture (moving it around).

Useful Note: 

1. The first few batteries inserted in each leg may experience a little binding as they try to find their way down the entire leg (chute).  A couple taps and shakes would get them all the way to the bottom.  But as each leg fills up with a few batteries, they become “self aligning” and would operate smoothly from then on. Alternatively you can use the tip of tweezers (thru the slot opening) to help the battery go down the leg.

I took this opportunity to try out a tri-color silky PLA filament (red-yellow-blue) that I thought would look great with this sculpture.  The color combination creates 6 different colors that varies depending on which angle you view it from. What do you think?

Also I experimented with a "Hilbert Curve" top and bottom solid infill patterns to produce a multi-color effect on those faces.  The settings shown below are from the .3mf file that's attached.

Here is a close-up of the multi-color effect from the Hilbert Curve infill.

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Happy Printing!