3D Printed Operando Acoustic Holder for Coin Cell Batteries

Overview This CAD set contains the 3D printable files for a custom-designed compression holder used for operando active acoustic monitoring of coin cell batteries. The assembly is designed to securely align two ultrasonic transducers (emitter and receiver) on either side of a coin cell, maintaining consistent coupling pressure via a mechanical spring during electrochemical cycling.

This setup allows for the continuous monitoring of acoustic metrics (such as Time-of-Flight and signal attenuation) to study structural and mechanical evolution within the battery.

Bill of Materials (Hardware & Components) To replicate this experimental setup, the following non-printed components are required:

• Acoustic Sensors: 2x Ultrasonic Contact Transducers.

  • Diameter: 19 mm (~0.75 inch).

  • Connector: Side-mounted Microdot (10-32).

• Hardware:

  • 1x CR2032-size coin cell

  • 1x Mechanical compression spring (to maintain constant acoustic coupling pressure).

  • 1x M10 fastening bolt (for spring tensioning).

  • 1x M10 nut (for housing assembly, inserted as inset during the 3D print of retainer_cap).

  • 2x Flat disks with electrical connectors (for electrochemical cycling of the cell)

  • Coaxial cables (Microdot to BNC/SMA) connecting to the ultrasonic pulser/receiver.

3D Printing Specifications The provided 3D models (main housing, transducer carriage, and end-caps) are optimized for Fused Deposition Modeling (FDM).

• Material: PETG (Polyethylene Terephthalate Glycol)

• Infill Density: 40%

• Layer Height: 0.20 mm

Assembly Notes The primary housing accommodates the stationary transducer at the base. The coin cell is sandwiched between this base transducer and the top transducer, which sits within a sliding carriage. The spring is sandwiched between the bottom_cap and top_cap parts, and screw assembly applies constant downward pressure onto the carriage, ensuring stable acoustic coupling throughout the charge/discharge cycle regardless of slight volumetric changes in the cell.
The nut must be inserted as inset during the 3D print of the retainer_cap part.