DIY Power Supply: How to Design, 3D Print, and Wire a Battery Holder (Tutorial)

🔴 Prototype with PCBWay Get a $5 credit on your first order here: [https://pcbway.com/g/908Dno] *UPDATE: You asked for it, and it’s here! 🚀* If you want to take your FreeCAD skills to the next level, I just released a follow-up video showing how to use a *Parametric Workflow* (Spreadsheets) to automatically generate 3D printed models just by changing a few numbers. We use it to build a watertight, custom PCB enclosure: 👉 *Watch it here:*    • How To Design Custom PCB Enclosures - From...   Stop buying generic battery holders that don't fit! In this video, I walk you through the entire process of designing, 3D printing, and wiring a custom snap-fit AA battery pack from scratch. I went through 13 iterations (and a lot of scrap PLA) to dial in the perfect tolerances so you don't have to. We cover Design for Assembly (DFA) in FreeCAD, the specific Cura settings you need (like Ironing and orientation), and a "lickety-split" soldering technique to wire up 3.3V and 5V packs without melting your print. Whether you need a single LiFePO4 cell or a series alkaline pack for your ESP32, this design has you covered. 📖 *Read the Full Guide (Wiring Diagrams & Photos):* [https://bj-dehaan-solutions.com.au/ar...] 📂 *Download the Files (FreeCAD Source, STLs, Cura Profile):* [https://github.com/Ben-BJD/DIY-Power-...] Big thanks to PCBWay for sponsoring this video; they provide professional PCB manufacturing, CNC machining, and industrial 3D printing services to turn your prototypes into production parts. Get a $5 credit on your first order here: [https://pcbway.com/g/908Dno] *Related Videos:* 🔑 Master your First Layer (Keychain Tutorial): [   • 3D Print a Keyring Like Magic – FreeCAD Tu...  ] ⚡ The Custom ESP32 Board used in this video: [   • Save Battery Life on Your ESP32 - How to M...  ] *Timestamps:* 0:00 The 13-Iteration Journey 1:06 Printer Maintenance & Bed Leveling 2:01 Safety Warning: Don't Short Your Calipers! 2:41 Understanding 3D Printing Tolerances 3:19 Designing the Snap-Fit Terminals (FreeCAD) 4:56 The "Cross Section" Hack 5:51 Moving from Prototype to Production 6:14 Critical Cura Slicer Settings 6:44 Wiring & Soldering (Without Melting PLA) 8:03 Voltage & Circuit Testing 9:19 Conclusion #3dprinting #freecad #electronics #diy #maker #esp32 #rapidprototyping