DIY 20,000mAh Homemade Powerbank – 3D Printed Edition

Welcome to this DIY project where you’ll build a powerful 20,000mAh power bank using minimal materials, a 3D printer, and basic electronics skills. In this instructable, you’ll learn how to combine printed parts, an IP5328P charging module, 4×18650 cells, and a custom battery holder (made from aluminum and wire) to create a fully functional and attractive portable charger. Follow along through my step-by-step guide with clear images for each process!

Materials:

1. PLA Filament: For 3D printed parts
2. Printed Parts: Printables (link here)
3. IP5328P Module: Charging and power management
4. M3 Screws (x4): For mounting the module
5. M4 Screws (x2): For mounting the case
6. 18650 Cells (x4): Lithium-ion batteries
7. Aluminum Strip: For constructing the battery holder
8. Aluminum Wire (or equivalent): To wrap the battery holder for mechanical pressure and conductivity

Tools:

1. 3D Printer
2. Screwdriver set
3. Soldering iron and solder
4. Wire cutters/strippers

3D Print the Parts

1. Download STL Files: Head over to Printables page to download the STL files for all required printed components. (link here)
2. Printer Settings: Use PLA filament and adjust your printer settings for optimal layer adhesion.
3. Printing: Print each part and lay them out for the next steps.

Install the IP5328P Module

1. Placement: Locate the designated space in the printed case for the IP5328P module.
2. Mounting: Secure the module using the 4× M3 screws. Ensure that it sits firmly in place.

Assemble the Battery Holder

1. Prepare the Holder: Cut a piece of aluminum to form the battery support.
2. Create the Contact: Wrap the aluminum strip with aluminum wire (or your preferred conductive wire) so that it provides a strong mechanical pressure. This ensures a secure, conductive connection for the battery cells.
3. Flexibility: Note that you can experiment with different materials (such as using a different metal or wire) as long as the connection is stable. You can also spot weld the connection for better stability and reliability.

Soldering Connections

1. Wiring: Solder the necessary connections between the IP5328P module, the 18650 cells, and the output wiring.
2. Safety Check: Verify correct polarity and insulation before powering up the device to prevent short circuits.

Final Assembly

1. Integrate Components: Fit the battery pack into the printed case along with the mounted module and battery holder. Mount the case with 2x M4 screws.
2. Secure: Ensure all parts are firmly in place and that wiring is neatly tucked away.
3. Completion: Once assembled, test the power bank to confirm it is working correctly.