Second version of my low-cost DIY soldering iron: upgraded to Li-ion power plus a printed shell, more convenient to use

Home-built soldering station, version 2: 6 Li-ion cells + BMS + 3D-printed shell; fish paper on the positive ends, cells laid out to the BMS wiring, welded with the AWithZ supercapacitor spot welder at gear 10 using the manual-button pen, balance leads and power leads soldered on; twin switches (battery / main board), external-power charging port, sleep connector, assembled and test-soldered

Lots of people in the comments showed their own home-built soldering irons, so the creator upgrades his earlier DIY soldering station: materials are 6 Li-ion cells, 1 BMS, and a self-designed 3D-printed shell (came out well). Battery welding: fish paper on the positive ends for insulation, cells positioned to match the BMS wiring; welded with the AWithZ supercapacitor spot welder at gear 10, the pen with the manual button is convenient; weld the cells, the BMS balance leads and the power leads in turn, then insulate the battery. Main unit assembly: on the rear panel the left switch controls the battery and the right switch the main board, external power and charging port on top, sleep connector below; fit the main board with four screws, secure the battery and wire it as required, mind the polarity; fit the rear panel and it’s done, the outside fits together seamlessly; plug in the handle and the sleep socket, switch on the battery and the main board, and solder a board to test. Comments: one viewer reports an AWithZ that ‘starved’ twice after sitting for half a year — the first time it revived after a day and night on charge, the second time it didn’t after 36 hours and went back to the factory; don’t buy the big-capacitor type if you rarely use it (creator: didn’t know that could happen); T12 mod enthusiasts; some find the accessories over-complicated, simplicity is best.

Outcome

Steps5 steps · click a frame to jump

1. 
   1. Upgrade materials: 6 Li-ion cells, BMS, 3D-printed shell

   People in the comments showed their home-built irons; upgrading the earlier DIY station; materials are 6 Li-ion cells + BMS + a self-designed 3D-printed shell, which came out well.

   00:00 – 00:15
2. 
   2. Fish paper on the positive ends, cells laid out to the BMS wiring

   Put fish paper on every positive end for insulation; position the cells as the BMS wiring requires.

   00:15 – 00:22
3. 
   3. AWithZ supercapacitor spot welder, gear 10, manual pen

   Using the AWithZ supercapacitor spot welder at gear 10, the pen with the manual button makes welding convenient; weld the cells, balance leads and power leads in turn; insulate the battery.

   00:22 – 00:36
4. 
   4. Main unit assembly: twin switches, power / charge port, sleep port

   Rear panel, left switch for the battery, right switch for the main board; external power and charging port on top; sleep connector below; main board with four screws; secure the battery and wire it, mind the polarity; fit the rear panel, done.

   00:36 – 00:54
5. 
   5. Fit the handle and sleep socket, power on and test-solder

   The outside fits seamlessly; plug in the handle and the sleep socket; switch on the battery and the main board; solder a board to test.

   00:54 – 01:09

Bill of materials

Creator’s tips

• Fish paper on the positive ends first, then lay out the cells to the BMS wiring 00:15
• The manual-button pen makes welding convenient 00:26
• Twin switches control the battery and the main board separately 00:36

Pitfalls

• Comments: an AWithZ big-capacitor unit starved twice after sitting half a year and went back to the factory; don’t buy the big-capacitor type if you rarely use it

Li-ion safety

• Mind the battery polarity when wiring the circuit 00:44

Quotes