DP-6 EBike Battery Case Top Shell

Im going to write this later, Im just going to post this and deal with it later

Differences between models:

Regular Size: 94mm Tall

Enlarged Size: 110mm Tall

Generic: Removes the voltage and amp hour text on the side of the case

RMB: The one I use on my personal bike with a feature to stabilize on a 32mm 60deg seat tube to down-tube angle and 48V 13Ah label

Print Settings & Material Selection:

• 0.4mm Nozzle Required

• 0.2mm Layer Height Recommended

• 3 Shells Recommend

• Brick Layers or similar Recommended

The top lip has around 0.8mm features that want to be printed with a 0.4mm nozzle. Arachne slicing can work with a 0.6mm nozzle but 0.4mm is better.

Yes, its a 15h print and requires like a 350x350mm build plate.

Most materials are fine

The geometry and usage wants as much layer adhesion and toughness as possible.

Nylon and PC-ABS blends are recommended

PLA works so long as the battery doesnt get crazy hot.

Purpose:

This shell was designed to replace several broken shells on DP-6 batteries.

Issues encountered and improved include:

• Crack shells

• Broken threaded pillars

• Being unable to accommodate a JBD BMS upgrade

• Not being able to be printed for around 5 CAD whenever I smash the top of my battery on a rock

What is a DP-6 EBike Battery?:

A DP-6 battery is a "standard" shark type battery that is popular with custom ebike builders.

It is probably one of the most popular types along with the variants of the hailong type.

The DP-6 type can be identified by the shape and location of the electrical contacts (Figure 4).

The battery has a 5 contact connection located at the bottom of the battery.

Additionally, the battery has a small locating feature at the very end, between the bottom 2 screws