Engineering / Masswell Advanced Energy Systems
Printed enclosures for a forklift battery
Five 3D-printed enclosure parts for a lithium-ion forklift battery, shipped inside a battery delivered to a client.
- Organisation
- Masswell Advanced Energy Systems
Erciyes Teknopark, Kayseri - Period
- Aug – Sep 2025
- Role
- Mechanical Design Intern
- Tools
- SolidWorks, FDM 3D printing, PLA, Heat-set inserts
Problem
A lithium-ion forklift battery needed five enclosure parts: a BMS housing, a fire safety holder, a power supply container, a resistor case and a screen mount.
What I did
- Built all models in SolidWorks from physical measurements.
- Printed them in-house in PLA and re-tuned tolerances when parts failed.
- When the mounting columns fractured, applied FDM anisotropy principles — reoriented the print axis and added fillets at the stress concentration points — fixing the failure without adding material.
Result
All five components shipped inside a battery delivered to a client.
Failure and fix
The first mounting columns snapped at the base. FDM parts are weakest between layers, so the fix was geometry and print orientation, not more material.
BMS housing
Power supply container and fire safety holder
Screen mount
In the battery
