18650 cell USB charger for TP4056

Yet another charger housing. I found several similar things here, most are made to fit the (old?) PCB layout of the TP4056. Found few for the new PCB, but didn't really like the unprotected PCB and other detail.

Now this is to be used with the new layout TP4056 PCB (easy to recognize with the two small tabs on the PCB opposite side of the USB socket, see the model by Robin https://www.thingiverse.com/thing:3626660).

I used the famous https://www.thingiverse.com/thing:2668159 as battery holder. Alex' design is for me by far the best, the integrated pull-spring works very good, and with a well calibrated printer it works right of the print bed.

The cover plate should snap in, if it does fit to loose, use some CA glue to secure it.If it can't be pushed in, trim it with a sharp knife.

The cover has a small very thin section to allow PCB LEDs to shine through, these are very bright in general on these PCBs.

Update per march, 3rd 2023: Added a new, improved version of the cover. I realized that during charging the PCB gets warm, so I thought some air vents would be a good idea - though I am not sure if they are really required. Also, the section in the cover above the LEDs is now optimized - see the new photos.

Print Settings

Printer Brand:

Creality

Printer:

CR-6 SE

Rafts:

No

Supports:

No

Resolution:

0.2

Infill:

50%

Filament: Quality stuff! There are HUGE differences in strength PLA, PETG

Notes:

Give it at least 50% infill to strengthen the movable part. NO SUPPORT needed!

Assembly, soldering instructions

As contacts I used "Musterklammern", see pictures here: https://de.wikipedia.org/wiki/Musterklammer
First solder wires to the PCB, determine length (negative wire can be glued into the small notch on one side of the holder - see attached Tinkercad-screenshot)

Insert the PCB into the holder, make sure the two small tabs enter the holes facing the battery side, and the USB socket fits into the groove on the other side. (see attached Tinkercad-screenshot)

Tin- coat the "Musterklammer" before installing with your soldering iron, to keep actual soldering to the wire short for not melting the PLA thing.

Put "Musterklammern" through the holes, solder wires to them, push cover plate into place (the side with the longer tab goes over the USB-socket).

here you are.

How I Designed This

Modified the source objects and added parts in Tinkercad