Doubling The Capacity of Power Tool Batteries

YouTube User [Vuaeco] has come up with a novel idea, combining power tool battery packs to double the capacity.

Starting off with two slimline 2.0Ah compact battery packs, [Vuaeco] wanted a larger 4.0Ah rebuilt drill battery pack. These battery packs are different in size so it wasn’t just a case of adding in more cells in empty slots, instead he goes on to show us how to connect the batteries in parallel using some thin nickel strips. Once completed he modifies the battery casing so it fits another stack of batteries. He does this by bolting the top and bottom together with long screws, and insulating the otherwise exposed battery terminals with insulating tape. The final product isn’t as aesthetically pleasing as a real battery pack, but it looks good enough.

There are a few things we might have done differently, for instance providing some hard plastic around the insulation so should the battery get knocked in an awkward position it would still have a hard shell protecting it. Also, instead of combining the batteries together fully charged as the video suggests, we might have done the opposite approach and fully drained them, avoiding unnecessary risks. If you try this, how about giving it a 3D printed case?

Continue reading “Doubling The Capacity of Power Tool Batteries”

3D Printed Battery Forms

What’s the worst thing that can happen when you are trying to show off a project? Dead batteries might not be the absolute worst thing, but it is pretty close to the top of the list. [KermMartian] has this problem every year at World Maker Faire with demos based around calculators. At first, he tried wedging power supply wires into the calculator using dead batteries to hold the wires in place. However, it didn’t take much wear and tear before the wires would pull out.

The solution? A 3D printed battery form that accepts metal hardware that can connect to the external power supply. The AAA-sized plastic batteries insert into the calculator’s battery compartment and the small machine screws and washers form the connection points.

Continue reading “3D Printed Battery Forms”

Could Solid-State Batteries Last a Lifetime?

Researchers from MIT and the Samsung Advanced Institute of Technology have been developing a new material that could potentially revolutionize the battery industry. A solid electrolyte that won’t wear out, lasting exponentially longer than current battery chemistry.

It also has the possibility to increase battery life, storage, and the safety of batteries — as liquid electrolytes are the main reason batteries catch on fire.

Sound too good to be true? The idea for solid-state batteries has been around for awhile, but it sounds like MIT and Samsung may have figured it out. The current materials used for solid electrolytes have difficulty conducting ions fast enough in order to be useful — but according to the researchers, they’ve discovered formula for the secret sauce. They’ve published their findings on, which is sadly behind a pay wall.

Another great benefit of solid-state batteries is they would be able to operate at freezing temperatures without a problem. What do you think? Is Samsung blowing smoke, or will they actually release a battery you never have to replace?