How to make 18650 battery holder? 3 useful methods

18650 batteries are extremely popular for powering devices like flashlights, vapes, and more. However, one of the challenges with using 18650 batteries is how to house and connect them properly. Making your own 18650 battery holder is actually quite simple with just a few basic materials.

In this DIY guide, as a professional 18650 battery packs manufacturer, I’ll show you three methods for creating an 18650 battery holder so you can utilize these batteries safely and effectively in your next project.

Why you need a battery holder

An 18650 battery holder serves a few important purposes:

• It protects the batteries and terminals from short circuits and damage. Without a holder, the battery terminals could inadvertently touch metal surfaces or each other, causing dangerous shorts and potential explosions or fires.
• It neatly organizes multiple batteries, keeping everything properly aligned and spaced. This allows for simpler wiring and connectivity.
• It enables easy insert and removal of batteries for charging or replacement. A good holder lets you quickly swap batteries without hassle or risk of shorts.

So in short, an 18650 battery holder is a must for safely harnessing the power in these batteries. While you could try taping batteries together as a makeshift solution, I strongly advise investing the small amount of time and money to construct a proper holder. Your project (and safety!) will thank you.

How to make 18650 battery holder

Method 1: 3D printed battery holder

One of the simplest ways to make a custom 18650 battery holder is by 3D printing one that perfectly fits your needs. With a quality 3D printer, you can produce battery holders in just about any configuration imaginable.

Designing the 3D model

I recommend using Fusion 360 or Tinkercad to design your battery holder. Both are free for personal use and relativity easy to learn.

When designing your holder, be sure to accurately measure your batteries so you can produce proper cutouts for each cell. Most 18650 cells are 18mm x 65mm, hence the name. Design your holder with cutouts just slightly larger than 18 x 65mm so the cells can slide in snugly without too much play.

You’ll also want to allow adequate spacing between the battery terminals. I suggest at least a 3mm gap between cells, or more if you plan on running higher voltage/current through them. This spacing prevents shorts.

Finally, add some type of enclosure around the batteries to protect the sides and terminals. This could be a full enclosure with a lid, or even just thin walls separating the batteries. Get creative!

Printing and assembling

When printing your design, I recommend using PETG or ABS filament as these materials will best withstand heat. PLA may be suitable for lower-power applications.

Print your holder solid with good infill, at least 40%. This gives the holder strength and structure. I also suggest printing a couple spares just in case one breaks.

Sand any rough edges, then do a test fit with your 18650 batteries to make sure they slide in and out smoothly without binding or getting stuck. You may need to re-print with slight size adjustments to get that perfect fit.

That’s it! Now you’ll have a custom holder tailored exactly to your batteries and project requirements.

Method 2: PVC 18650 battery holder

PVC provides an inexpensive way to produce a durable and weather/heat resistant 18650 battery holder. And it requires nothing more than some simple PVC piping and endcaps from your local hardware store.

PVC materials

For the actual battery holder, you’ll want 1/2 inch PVC pipes and joiners. The 1/2 inch size allows 18650 batteries to slide in and out easily. You’ll also need 1/2 inch endcaps to seal both ends.

In addition to the piping, you’ll need a drill with various sized bits to drill holes for wiring, along with some supportive materials like hot glue and zip ties.

Finally, paint is optional if you wish to color code your battery holders. Rustoleum spray paint works well for PVC.

Constructing the PVC holder

Start by cutting a length of 1/2 inch PVC tubing that matches your desired number of 18650 cells. For instance, three 18650 cells would require a pipe length of around 7 inches.

Drill a hole near each end of the pipe. These holes will allow your negative and positive wiring connections.

Then drill small holes spaced evenly down one side of the pipe. These holes allow you to run zip ties through the inside and safely secure your batteries.

Now insert your batteries positive-end first into the pipe, making sure batteries are snug but not jammed together. Gently pull your zip ties over the batteries and cinch them down moderately tight. This prevents battery movement inside the holder.

Finally, glue your endcaps in place using hot glue or PVC cement. Attach your positive and negative wires through the wiring holes, then test for conductivity across your whole pack.

Repeat these steps to produce multiple battery holders, color coding them with spray paint for easy circuit identification. Custom PVC holders enable worry-free battery installation and industrial-level durability.

Method 3: Open frame hard drive 18650 battery holder

Repurposing old hard drive caddies is an eco-friendly way to fashion very durable and good-looking 18650 battery holders. Hard drives have super strong open frames designed to secure their internal components, making them suitable for housing batteries too.

Hard drive holder materials

First, you’ll need at least one 3.5 inch hard drive. Older style hard drives with thick metal framing work best, as newer drives have thinner plastic frames.

You’ll also need various wires, shrink tubing, soldering equipment, hot glue, and basic hand tools like snips and pliers. High temperature paint is also great for color coding your holders.

Constructing the hard drive holder

Start by fully disassembling your old hard drives. Remove all the internals so you’re left with just the outer metal framework and circuit board.

Determine how many batteries you’ll be housing in each holder. Then measure and cut heavy gauge wire into pieces long enough to contact both battery terminals. I suggest 16 gauge wire to withstand high current draw.

Solder your wires at alternating polarities to the hard drive circuit board. For example, solder one 14cm positive lead, then one 14cm negative lead beside it. Repeat this alternating polarity soldering for the total number of batteries your holder will contain.

Slide your first battery positive-end first under the positive wire, followed by the next battery under the negative wire, etc, until all batteries are installed in alternating polarity as secured by the wires.

Once wired up with all batteries inserted, test your holder for conductivity across the whole pack. Then hot glue batteries into place and secure connecting wires with shrink tube.

Finally, spray paint your framed holder for weather protection and easy circuit identification. Hard drive battery holders provide industrial level construction that can withstand abuse and element exposure.

Summary

Constructing your own 18650 battery holder is simple and enables custom solutions for properly harnessing the power in these batteries for your personal projects.

I encourage you to experiment with the techniques covered here – 3D printed holders, PVC piping holders, and hard drive refashioned holders. Producing custom battery holders ensures safe connectivity and handling of 18650 cells for worry-free charging and installation.

Let me know in the comments section if you have any other clever methods for fashioning 18650 battery holders!