Snap-fit copper-tab covers

Problem

Sunrider’s pack had a lot of exposed copper on the module tabs. The covers had to be removable, printable, and stay clear of the lid seal and existing fasteners.

What I designed

• Three SolidWorks covers: a snap-fit into rectangular cutouts (then thinned for print time), an end-module cover with fewer attachment points, and a two-part cover for curved copper that used existing bolts.
• Snap-fit headlight covers and protective boxes for custom boards.
• Rewired the pack when the custom BMS went in.

Printed in PLA/PETG. The car completed 1,465.8 miles in ASC 2024.