Build Your Own LiPo Battery Pack Method

Released on May. 24, 2022

 Build Your Own LiPo Battery Pack Method

If you want to assemble your own lithium polymer batteries, then you have come to the right place. lipo battery pack method has become so popular because the batteries are cheaper compared to other batteries. On top of that, you can recycle old batteries and still have a unique form factor.

Building a lithium polymer battery pack is very easy once you know what you are doing. You have to connect all the cells in series, but you need to use a separate balancer port.

Can you build your own LiPo battery pack?

Yes, you can build your own LiPo battery pack using old or new batteries. You need to have the right tools to do this. In addition, you can even use old batteries from devices such as laptops, drones and cameras. However, you should be aware that fat cells are very dangerous, especially when shortened. In addition, overheating, bending or they can release toxic particles or even cause a fire.

Please be careful when carrying fat cells with you at all times. You will need the following tools to build your lipo pack.

LiPo batteries (you can also use LiFePo). You can buy batteries or recover them from an old device like a MacBook. In addition, you can use a minimum of one cell, but this does not require much setup. You can get more capacitance by using more batteries. 

2. Main Power Connector - If you are setting up a high power usage pack, it is important to use the maximum rated power connector. Otherwise, you can use a normal connector such as the XT-60 or a flying helicopter. You will also need the balancer cable to make sure it is compatible with your charger. 

3. Silicon cable for use with the main power cable - Choose the right thickness of wire for your maximum power consumption. Silicon cables are best because they are safe, very flexible and do not overheat. Do not use poor quality cords, such as speaker cables, as they can cause fires. Also, make sure there is a tape to isolate things

4. Shrinkwrap-you need a small one and a large one. In addition, you need to make sure the shrinkwrap can be mounted on the main power cord. In addition, you need to make sure you have another item that fits in the entire package. It helps add some protection and keeps your cells together.

Build Your Own LiPo Battery Pack Method

How do you make your own lithium polymer battery pack?

Making your own lithium polymer cells is easy as long as you have the tools mentioned earlier. After confirming that you now have all the tools, you can follow these simple steps.

Step 1; Check your cells - If you bought them from a store, you can skip this step. However, if you salvaged them from an older unit, then you need to confirm that they are still working. In addition, you will need to keep track of the plus and minus signs.

A multimeter will help you measure all of these. If your old batteries are well below the minimum charge, then you will have to charge them using an external power source. However, please note that there is no guarantee that you can restore the original capacity and this is also dangerous.

Step 2; Design - Next, you decide to design the package for cutting the cables. All your connections need to be between negative and positive serial. In addition, the main serial power supply needs to be connected to each bridge from the endpoint and balun ports. The next step is to decide where your cables and connections can exit. Finally, make sure your cables are ready for soldering.

Step 3; Main Power Connector Setup - You will need to solder all power cables to the connectors while checking for proper polarity. If you have thicker wires, make sure you have something to hold the connector in place. It is also important to check that the wires are well soldered during this step.

Step 5; Add bridges, power connectors and balancer ports - Carefully integrate the bridges one after the other into your package. Use tape to isolate them to avoid accidents. Next, you can add the main power connector. You can now carefully connect it to the balancer to avoid losing the bridge. Finally, you can close the battery pack, label it, and also shrink wrap it to your satisfaction.

How do LiPo battery packs work?

Lithium polymer batteries, often referred to as LiPo, are now becoming increasingly popular. Everyone who needs high power and long term power now wants to use LiPo. But do they understand how it works? Very few people do. As long as you follow the instructions and treat them well, they will serve you well for a long time.

The main benefits of lithium batteries are: light weight, high capacity and high discharge rate. Since nothing is perfect, they also have some disadvantages. For example, they have a much shorter life span and also require a lot of care and attention. Many lithium batteries contain a plastic bag called a pouch cell. They are very effective for building multi-cell battery packs.

Soft pouch cells hold all cells securely and do not leave any gaps like round cells do. In addition, soft pack batteries are lighter compared to metal cans, thus making them the preferred choice for aircraft applications. By comparison, lithium-ion batteries are 20% heavier than regular lipo pouch batteries.

Because of their flexible pouch shell, LiPo pouch batteries allow for more outgassing and thermal expansion. In addition, when you open the battery, you will find a polymer inside, which is a thin plastic microporous film. It sits inside the copper anode, cathode electrode and lithium-coated aluminum. However, they are all laminated, alternating from the back and front of the polymer diaphragm to each other.

Sometimes long films over seven feet long can be folded into alternating cathode/anode stacks. In addition, a thin continuous polymer separator layer is inserted to separate them. If your fat cells leak at any given time, do not use it. Press the bag under some pressure before final heating and sealing. This helps to remove any air trapped inside before it is ready to be used.

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