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

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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.

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⚠️ 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.

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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!

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🚀 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.

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📂 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:

1. 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

2. 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

3. 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

4. Order the conductive tape

   • Conductive tape
     • ENSURE the '10mm' & 'Conductive on both sides' options are selected

5. 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

6. 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!

7. Build the Powerbank!

   • Follow along with the Youtube video

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🧾 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.

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🤝 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.

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🌟 Acknowledgments

A big thank you to:

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

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