E-bike 3D battery box generator from photo + cell brackets

[piotrrs11]

Hey,

I just published my generator of ebike battery boxes - Framebox — 3D printed e-bike battery box generator | generator skrzynki e-bike
It is free, feel free to give me a feedback of feature requests.

First of all video how it works:
Generating battery box from photo

Generating battery box from photo (VIDEO)







How it works:

Module 1 - custom frame box​

1. Upload a side photo of the frame, avoiding wide-angle distortion.
2. Calibrate scale by marking a known length and entering its value in mm.
3. Trace the frame triangle; adjust points as needed. The app creates a closed, smoothed outline for a hollow box.
4. Add M5 bottle-bolt mounts; the backend snaps them to the wall and prevents collisions.
5. Add Ø3/Ø4 mm through-holes, with automatic even spacing for 3+ holes.
6. Set wall thickness, box depth, test heights, and an optional gasket groove.
7. Generate two test fits: a 3 mm outline/boss test and a 14 mm M5 test with real holes, screw-head pockets, and groove. A 1:1 PDF paper template is also included.
8. Export the full model as STL, STEP, FCStd, PDF, and report in one ZIP, with a live Three.js preview.

Module 2 - battery pack builder​

After defining the outline, you can create the cell layout:

• Choose 18650 or 21700 cells and set the series/parallel configuration, such as 2S10P.
• The optimizer finds a compact honeycomb layout that fits the real box outline.
• Series groups are built as physically connected clusters of exactly P cells, making the busbars practical to weld.
• Live stats show maximum fit, required and selected cells, voltage, Ah, and Wh.
• Cells can be swapped manually, and export is blocked when the pack does not physically fit.
• Generates two adjustable honeycomb holder trays and thin insulating end flanges that leave terminals exposed for welding.
• The 3D preview shows the box, trays, and all cells together.

Extras​

• Real generation queue with live FreeCAD stage, progress, and ETA.
• Entire project saves to one .framebox.json file.
• PL/EN interface, tablet-friendly layout, and on-screen guidance.

Not included: Framebox handles mechanical geometry only. It does not select the BMS, insulation, nickel strip, fuses, wiring, or welding parameters. Have the electrical build checked by someone experienced before powering it up.




http://ebike.sobierski.com/

 

[piotrrs11]

I’ve added a few cool new features:

• Much better 3D previews for every part, tray, and side panel.
• Automatic calculation of the best cell layout, including positive and negative terminals, a complete welding map, and guidance on where to place the main positive and negative connections.
• Intelligent routing to keep the main positive and negative terminals as close together as possible.
• Custom printer bed size. Larger printers can generate the enclosure in fewer parts.
• Splitting into more than two parts. Smaller printers can divide the enclosure into several printable sections and assemble them afterward.
• Printing side panels, including split panels. This is not the strongest possible method, but it should work well for city bikes.

To make the side panels stronger, internal cross-ribs are added. If a panel is split into multiple sections, the parts can be joined with rivets or screws. The ribs can extend inward toward the battery pack, so the outside remains clean and smooth.

The system also warns the user when there is not enough space for the ribs based on the selected battery type, cell height, and cell holders.

I’m also considering adding cable cutouts and different frame mounting options in addition to the standard bottle cage mounts.

 

[jahjah182]

Is the app down for maintenance?