vape-power-bank

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README

Disposable Vape Powerbank Project

This repository contains everything you need to build a functional 100W power bank using lithium-ion cells salvaged from disposable vapes.

📺 Watch the Video

See the entire build process in action on my YouTube channel:

Watch on YouTube

This powerbank is an upgrade from my initial design and is now smaller, lighter, safer, and easier to assemble. It’s a fantastic way to repurpose vape batteries and contribute to reducing e-waste while learning valuable electronics and 3D printing skills.

⚠️ Disclaimer

This project involves handling lithium-ion batteries, which can be dangerous if mishandled. By using these designs or instructions, you acknowledge and agree to the following:

You assume all risks associated with the assembly and use of this project.
This project is provided "as-is," with no guarantees of safety or performance.
Always take appropriate safety precautions and seek professional guidance if unsure.

Please read the full Disclaimer before proceeding.

Affiliate Links & Sponsorship Disclosure

This repository contains affiliate links to suppliers and services. If you use these links to purchase parts (from Aliexpress) or sign up for services (such as JLCPCB), I may earn a small commission at no extra cost to you. These links help support the development of this project and my YouTube channel.

Thank you for supporting my work!

🚀 Project Overview

In this project, you will:

Extract lithium-ion cells from disposable vapes.
Test and prepare the cells for use.
Assemble a 3D-printed cell holder and enclosure.
Install custom PCBs to balance charge the cells and wire them up to form a 5S7P (5 cells in series, 7 cells in parallel) battery pack.
Wire up a fast-charge USB powerbank board.

Key Features:

Doesn't require directly soldering the cells together.
Multifunction PCBs (balance charging and power delivery) to reduce parts cost.
Open-source PCBs & 3D prints for easy customization and collaboration.
Supports 100W USB C PD charging.

📂 Repository Contents

This repository is organized as follows:

Disposable-Vape-Powerbank/
├── README.md           # Introduction and instructions
├── DISCLAIMER.md       # Full project disclaimer
├── LICENSE             # Project licensing details
├── PCB-Files/          # PCB related files
│   ├── Production-Files/   # PCB files for ordering
│   ├── Schematic.pdf       # PCB schematic
│   └── KiCad_Project/      # KiCAD project files
├── 3D-Models/          # Fusion360 files and links to printables
└── Images/             # Photos and renders of the project

🛠️ Quick Start Guide

Follow these steps to build your own disposable vape power bank:

Download Files
- Click the green Code button and select Download ZIP. Then extract the repository files.
- or clone the repository: git clone https://github.com/username/Disposable-Vape-Powerbank.git
Order the PCBs
- Head over to JLCPCB (or any other PCB ordering site)
- Sign up/Log in
- Head to the order page
- Upload the Gerber file from Disposable-Vape-Powerbank/PCB-Files/Production-Files/
- Refer to 10:13 in the project video for order settings
- Ensure 'Assembly' is checked
- Upload the CPL and BOM files
- Rotate the connectors to match the orientation within the video
- Place the order! If you get an email asking if the polarities of the springs are correct - reply that they are
Order the USB board
- USB board - Type 1 (Recommended - Used in the video)
  - ENSURE THE 5S OPTION IS SELECTED
- USB board - Type 2 (More USB C ports - requires different 3D prints to the video)
  - ENSURE THE 5S OPTION IS SELECTED
Order the conductive tape
- Conductive tape
  - ENSURE the '10mm' & 'Conductive on both sides' options are selected
Order optional extras
- Right angle JST connector
  - ENSURE XH2.54MM, Length 10CM, 4P IS SELECTED
  - Not essential but makes wiring the board slightly easier
- 8 Channel Cell Tester
  - Also not essential
  - Allows you to match the battery capacities for each parallel row - improves powerbank battery life & lifespan
  - Good if you regularly do battery related projects
Print the parts
- Easiest: Find the right size on printables Or
- Download the cell holder from the 3D models folder
- Download the enclosure from the 3D models folder
  - Select the enclosure depending on your board type
- Print out the parts!
Build the Powerbank!
- Follow along with the Youtube video

🧾 Licensing

This project is licensed under the MIT License. You are free to use, modify, and distribute the files, provided you include proper attribution and accept the project’s disclaimers.

🤝 Contributions

Contributions are welcome! If you have suggestions, improvements, or issues, feel free to:

Open an issue in this repository.
Submit a pull request with your changes.

🌟 Acknowledgments

A big thank you to:

JLCPCB for sponsoring the youtube video/project.
Everyone who has supported and engaged with my Youtube channel.

Enjoy building your power bank and contributing to e-waste reduction!

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