Build Your Own 4S Battery Pack

Having a flexible and modular battery pack is essential for many DIY projects. That’s why I designed this 4S Battery Pack PCB, allowing for easy battery installation and removal. Unlike traditional soldered battery packs, this design lets me swap out batteries effortlessly, making it perfect for temporary or reusable setups. Whether for RC projects, portable power applications, or testing different battery cells, this PCB simplifies the process while ensuring a secure and reliable connection.

A special thanks to PCBWay for providing high-quality PCBs that made this project possible. Their precision manufacturing and excellent build quality ensured a flawless and durable design!

Components

1. 18650 Battery
2. 4s BMS
3. XT30 Connecter
4. 4s Battery Holder
5. Costum PCB

Tools

1. TS80P Soldering Iron
2. Xtar VX4 Smart Charger
3. Soldering Wire
4. Helping Hands

First step is getting started with design the PCB, for design the PCB - main credit goes to Steve Willson. It includes 4s Battery Slot at front side & XT30 male - female connector for power input and output. Also at the other side there is place of 4s BMS (Battery Management System) for the safety of battery pack.

You can get the Gerber file from the given link.

For PCB Prototype I always choose PCBWay because PCBWay is famous for its top-notch quality, precise manufacturing, and affordable pricing. Whether you're a hobbyist or a professional, they provide fast delivery and excellent customer support, making them the go-to choice for PCB manufacturing

Ordering a PCB from PCBWay is super simple and rewarding! Just sign up using this link and get your first PCB for free. Once registered, upload your Gerber files by clicking "Quote Now," choose your specifications, check the pricing, and confirm the details. After that, place your order, make the payment, and let PCBWay handle the rest. Your high-quality PCB will be manufactured with precision and shipped to your doorstep.

After receiving the PCB from PCBWay, simple pleace the components one by one on PCB and start Soldering. First place 4s battery slot and both XT30 Connecter on at there place and solder them. Then at the back side place the 4s BMS on PCB and match the pads, once pad got matched, tin the first pin soldering iron and after that solder all the pads one by one and you're done! For better results after soldering, use ISO Propyl Alcohol to clean the PCB.

Now the PCB is completely assemble.

It's necessary to charge all the battery fully before making a battery pack. So For charging the batteries, I'm using the smartest battery charger – the XTAR VX4! This high-performance charger is designed to safely and efficiently charge a wide range of Li-ion and Ni-MH batteries. With its intelligent charging system, it automatically detects battery type, adjusts charging current, and ensures optimal performance.

The VX4 features, Type-C Input, 4 independent slots, and a fast-charging mode for quick and reliable charging. It also includes multiple safety protections, like overcharge, short circuit, and temperature control, making it a must-have for battery enthusiasts and professionals. Power up your batteries the smart way with the XTAR VX4.

After fully charging the PCB with a specific Charger like VX4, place all the battery carefully at its slot one by one. After installation of all batteries, this project is completely ready to use.

While testing it performed better than I expected, I tested multiple things like LED, heating element, 35w filament bulb and yeah, it performed very well.

In my conclusion, this project is the best use, whenever you want a battery pack without loosing your batteries permanently in pack. After use just remove the batteries from slot and use it at any other place. Also it's a cheaper than your battery pack!