CNC Router Project - Battery Charging Station for Dewalt Batteries

 

Dewalt 20v cordless battery charging storage holder made from plywood with amana CNC Router endmills on a Avid CNC Router Pro4896 machine. Once assembled using screws, the battery holder is mounted onto a wall and the battery chargers are plugged in.

Project Info:

Item: CNC099 - Battery Holder Charging Station for Dewalt 20v Batteries

Date: 3/17/2023

CNC Router: Avid Pro4896

Software: Autodesk Fusion 360

Included File Types: Fusion 360 .f3d, STEP, Vectric Vcarve Pro CRV, DXF and SVG files.

 

Goals of Project:

My garage workshop is a small space with tools, material and items scattered all around. For a while I took to storing my cordless power tool batteries in one of the Milwaukee 2 Drawer Packout Tool Boxes but I didn't love this solution. Ultimately I thought creating an all-in-one battery charging and storage station for my collection of Dewalt 20 volt cordless batteries would be a fun project to 3D model in Fusion 360 and cut up on my CNC Router. 

 

Project Criteria:

  • Store at least 15 Dewalt 20v Batteries
  • Include 3 dedicated battery chargers
  • Have 1 large shelf for miscellaneous items
  • The ability to mount on a wall or store on a workbench

 

Materials & Endmills Used:

Disclosure: Contains affiliate links to Amazon.

Endmill: Amana Tool 46202-K Solid Carbide Spiral Plunge Router Bit Down Cut 1/4 Dia

Speeds & Feeds: 180IPM at 18,000 RPM

Material: 3/4" (19mm) Plywood 

Router Bits: Freud 34-104: 1/8" Radius Rounding Over Bit

Router Bits: Freud 42-104: 1/2" (Dia.) Bearing Flush Trim Bit

 

Prototypes:

It took me 3 rounds of 3D models and prototypes to dial all the details in. The first prototype was wasn't perfect but the main thing I focused on was how the batteries fit on the rack. On the second prototype I adjusted the angle of the battery holders, reduced the overall height and increased the depth of the shelf at the bottom of the battery rack and tweaked the mounting plate for the battery chargers. On the third and final rack I again made adjustments tot he mounting plate for the battery chargers as the cords were in need of a way to stay in one place.

 

Materials Used:

For this project I picked up a sheet of 3/4" (19mm) plywood from the local big box store. The sheets ran about $68 per sheet of plywood and are a pretty easy plywood to work with. The plywood I use is a Radiata Pine Plywood that is an ACX plywood and has one clean face and one face with knots. This material machines real easily on my CNC Router but on occasion warps real quick and I have trouble fixturing the sheet on my custom made CNC vacuum table. 

 

dewalt cordless battery charging station for charging and storing dewalt 20v batteries made from plywood on a cnc router machine

New Learnings From Project:

The big take away I had from creating this project came on the 3D modeling side of things and the "mirror" feature in Fusion 360. While this wasn't my first time using the mirror feature, it was the first time that I had altered my workflow with the intention of reducing the file size so that my computer could keep up with the larger file sizes. 

Before, I use to draw a full sketch of a part, turn it into a solid and then add fillets. This meant having a fully drawn part and filleting all of the necessary edges. Instead, when possible, I took the approach to only draw half of a part, turn that half into a solid and then fillet only that half. Once I did this, I then mirrored that half. This meant my computer was handling half of sketches and fillets in Fusion 360. 

in progress screen shot of a fusion 360 3d model using the mirror feature for bodiesin progress screen shot of a fusion 360 3d model using the mirror feature for bodies

 

Future Projects:

After launching this project on TikTok and Instagram a few requests for smaller versions of this Dewalt Battery Charging Station have been made. After receiving these requests, I've added to my project list a few smaller Dewalt Battery Storage projects for those with CNC Routers that are 24"x24" in size. 

 

CNC/Modeling Tips From Project:

Normally most projects go through the process of a quick sketch, a 3D model in Fusion 360, generate gcode in Fusion360, cut the parts on my CNC, assemble and put the project into use. 

As this project had a few more variables to account for, I opted to create a few prototypes and I had committed to this path before making the first prototype. Knowing I would be coming back to the 3D model to make revisions meant that developing a fully constrained 3D model in Fusion 360 would be the best way to ensure I could go back and make quick revisions without needing to rework my entire 3D model from the ground up on each prototype.  

 

Project Files:

If you'd like to pick up a set of project files for making your own battery rack to store Dewalt 20v batteries, here is a link: Battery Holder Charging Station for Dewalt 20v Batteries

 

Social Media Videos of Project:

Instagram: @dryforgecncwoodworks

TikTok: @dryforgecncwoodworks

 

 

Dewalt 20v cordless battery charging storage holder made from plywood with amana CNC Router endmills on a Avid CNC Router Pro4896 machine. Once assembled using screws, the battery holder is mounted onto a wall and the battery chargers are plugged in.
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