Ryobi 18V Battery latching connector (one-piece, no supports)

Latching connector for Ryobi 18V batteries. Prints in one piece, no supports, uses Keystone 209 battery contacts.
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updated February 10, 2024

Description

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This Ryobi 18V battery latching connector was designed to be simpler and better than the existing models: 

  1. Prints as a single piece
  2. No support needed
  3. Uses inexpensive Keystone 209 battery contacts, mounted so they can't slide off in use.
  4. Useful for other projects like battery conversions, chargers, etc.
  5. Just works

The result works great – will soon be publishing another model using the Ryobi 18V connector to power a USB charger. 

Parts required:

QtyPart
2“Keystone 209” Battery Connectors. Plenty on Amazon and Ebay. 
 example:  50pcs Keystone 209 Battery Contacts on Amazon
1Printed part
4medium flat-head screws if you plan to mount it. Size 4 or 6

 

Assembly Instructions (see pictures):

  1. print model with no supports. PLA, ABS or PETG are all fine. 
    - Make sure walls have are sliced with at least 2 lines thick, preferably 3. 
     
  2. solder the wires to the contacts before attaching to the printed part to avoid melting the part. 
    - Bend about 2-3mm of wire at 90 degrees and solder, so wire doesn't interfere with attaching connector
    - use solder flux for better solder adhesion to the contact
     
  3. Clip the contacts onto the side tabs, see pictures for installation. 
    - small flat blade screwdriver will help install the clips
     
  4. Print the template if you plan to mount the connector in a board or panel. Use the template to mark the installation cutout and mounting holes.

 

Note: if the battery doesn't snap in easily, shave a tiny bit off the latch “fingers” to help it snap shut.

Why did I design this? 

I appreciate the other Ryobi 18V connector models that have been out there for a number of years, but wasn't really happy with any of them. Some require printing and assembling multiple parts, some require a ton of supports, some have connectors that slip out of place during use, some are already built into a purpose-built device that I don't need/want. 

I just wanted something sturdy that works really well, is reliable in use, easy to print, doesn't require expensive connectors and is adaptable to a lot of applications. No doubt it can be improved, but IMO it's a step forward. Hope you enjoy it!

Designed in FreeCAD, which is a very powerful but also temperamental and cantankerous piece of software.

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