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I will create custom lithium battery pack enclosure dfm 3d cad fusion 360 solidworks
Julien Mathias
About this gig
Battery enclosures punish shortcuts. Too tight and cells swell into each other, too loose and the pack rattles apart, no venting and heat builds where it should not. I design lithium pack housings in Fusion 360 and SolidWorks around your real cells, with DFM applied so the part is actually producible.
What I design
- Lithium battery pack enclosures
- 18650 and 21700 cell housings
- LiPo pouch cell protective cases
- Cell holder and spacer layouts
- BMS mounting plates and brackets
- Busbar clearance and terminal guards
- Swelling allowance and cell retention
- Ventilation and thermal relief features
- Connector, switch and display cutouts
- Sealed and IP rated pack housings
- Mounting feet, rails and fixing points
- 3D print, sheet metal or molded versions
What you get
- 3D CAD models and assemblies
- STEP and STP for any CAD system
- Print ready STL or flat pattern DXF
- Native Fusion 360 or SolidWorks source
- Dimensioned PDF technical drawings
- DFM notes on wall thickness, draft and clearances
- Revisions based on your package
Send your cell type and count, pack configuration, BMS dimensions, connector details, target size and manufacturing method. Message me first so I can review the pack.
Delivery style preference
Please inform the freelancer of any preferences or concerns regarding the use of AI tools in the completion and/or delivery of your order.
Get to know Julien Mathias
Julien Mathias
INDUSTRIAL AND PRODUCT DESIGN
- FromFrance
- Member sinceOct 2026
Languages
English, French, German, Spanish, Italian, Portuguese
Tooling costs more than most cars, so I take draft angles very seriously.
I engineer plastic housings for medical devices, automotive ABS components, lithium battery packs, and countertop kitchen appliances, using SolidWorks, Creo, and CATIA with full DFM from the first feature.
Uniform walls. No hidden undercuts. Defined parting lines. Honest notes on what will and will not mold cleanly. You get a prototype STL to test, then a mold ready STEP your tool maker will thank you for.
Send your components and requirements. Let's build it properly.
FAQ
What do you need to start?
Cell type and quantity, series and parallel configuration, BMS and PCB dimensions, connector and switch details, target enclosure size and your manufacturing method.
Can you design around my existing cells and BMS?
Yes, send STEP files or measurements and I will build the housing around them with correct clearance, isolation and retention.
Do you allow for cell swelling?
Yes, I build in expansion allowance appropriate to your cell chemistry and format so the pack does not stress under load or age.
3D printed, sheet metal or injection molded?
All three. Tell me your method and I apply the correct wall thickness, draft angles or bend allowance.
Do you add ventilation and thermal features?
Yes, vent paths, airflow channels and heat relief geometry can be designed in based on your pack power. Formal thermal simulation is not included.
Can you make it IP rated?
Yes, gasket channels, sealed glands and drip shields can be designed in. Final IP compliance requires physical testing.
Do you provide battery safety certification?
No, this service covers mechanical CAD and DFM only. Electrical safety, cell validation, UN38.3 and certification must come from a qualified engineer and accredited lab.
Which formats do you deliver?
STEP, STP, STL, 3MF, F3D, SLDPRT, SLDASM, DXF, DWG and PDF.
Do you manufacture the enclosure?
No, I deliver design files only. You take them to your printer, fabricator or molder.
