Busbar Designer + Hex Holder Designer

Web "combine" for cylindrical-cell battery pack production. Two pages:

Page	Purpose
/holder	Parametric hex cell holder designer — adjust pack size / cell type, see 3D, download STL for printing.
/	Busbar designer — import cell coordinates, group into busbars (parallel + series), export STEP/DXF/SVG for laser cutting.

The holder page has a Design busbars → button that auto-creates a busbar project pre-loaded with the exact cell coordinates from the configured holder.

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Web tool for designing nickel/copper busbars over cylindrical-cell battery packs (21700, 18650, ...) built with hex-shaped cell holders.

Workflow:

1. Import cell-center coordinates (paste from OpenSCAD console, CSV, JSON — or generate from cell_dia / wall / rows / cols).
2. View cells on a 2D canvas at real mm scale.
3. Click cells to select; group selected cells into named busbars (parallel groups), then chain busbars in series.
4. Each busbar is drawn as a strip of configurable width with circular pads + welding-window holes over each cell center.
5. Export busbar geometry to STEP (mandatory), plus DXF and SVG for laser/waterjet cutting.

Quick start

Requires Python 3.10+ and OpenSCAD on the host (only needed for the /holder page; the busbar page works without it).

# Windows / PowerShell
cd busbar-designer
python -m venv .venv
.\.venv\Scripts\Activate.ps1
pip install -r requirements.txt
python app.py

OpenSCAD install: Windows — winget install OpenSCAD.OpenSCAD; Linux — apt install openscad.

Then open http://localhost:5000 for the busbar designer, or http://localhost:5000/holder for the hex holder designer.

First-time install pulls build123d (~ 200 MB; bundles OpenCASCADE via OCP) and may take several minutes.

Linux / macOS

cd busbar-designer
python3 -m venv .venv
source .venv/bin/activate
pip install -r requirements.txt
python app.py

Geometry source of truth

All cell-center math matches Addy's Hex-Cell-Holder/hex_cell.scad:

Variable	Formula	21700 default
hex_w	cell_dia + 2*wall	22.8 mm
hex_pt	hex_w / 2 / cos(30°)	13.164 mm
opening_dia	cell_dia − 2*cell_top_overlap	15.2 mm
row pitch (Y)	1.5 * hex_pt	19.746 mm
col pitch (X)	hex_w	22.8 mm
rect row shift	0 (even) / 0.5*hex_w (odd)	11.4 mm

Import formats

The importer auto-detects:

• OpenSCAD ECHO: ECHO: "Cell 1: x = 0.0, y = 0.0" (paste straight from console).
  • If your hex_cell.scad doesn't print these, drop scad_snippet.scad (in this repo) at the bottom of the file.
• CSV: index,x,y (header optional).
• JSON: [{"id":1,"x":0,"y":0}, ...] or [[x,y], ...].
• Generator tab: enter cell_dia / wall / rows / cols / pack_style — coordinates are computed with the exact OpenSCAD formulas.

Persistence

State is stored in a SQLite file (data/busbar.db by default; override with BUSBAR_DB env var):

Table	What
projects	Full editor state (cells + busbars + params) per project
presets	Named param bundles you save from the params panel
snapshots	Auto-history per project; max SNAPSHOT_RETENTION (default 20) kept

REST API (all JSON):

Method	Path	What
GET	/api/projects	list projects
POST	/api/projects	create {name, data}
GET	/api/projects/{id}	full project
PUT	/api/projects/{id}	update {name?, data?, snapshot?, note?}
DELETE	/api/projects/{id}	delete (cascades to snapshots)
GET	/api/projects/{id}/snapshots	list snapshots
GET	/api/snapshots/{sid}	full snapshot
POST	/api/snapshots/{sid}/restore	roll project back
GET	/api/presets	list presets
POST	/api/presets	create {name, params}
PUT	/api/presets/{id}	update
DELETE	/api/presets/{id}	delete

UI behaviour:

• Active project ID is in the URL: ?p=42. Bookmark or open from another device → same state.
• Auto-save fires 1.5 s after the last change. The first save in any 60 s window also creates a history snapshot.
• "History" button shows the snapshot list with a Restore action.
• Presets are saved server-side and apply to any project with one click.

Backup: the entire DB is one file. Copy data/busbar.db (or the data/ folder in Docker) for offline backup.

Export

Format	Use	Backend
STEP	CAD (FreeCAD, Fusion, SolidWorks)	build123d → OpenCASCADE
DXF	Laser cutter / CNC (2D)	build123d → ezdxf
SVG	Quick preview, illustrator	build123d

STEP files are written as flat 3D faces (not solids) so a fab shop can lay them out before cutting. If you need a thick solid (e.g., 0.2 mm nickel) toggle "Extrude busbars" — the backend will extrude each strip to the configured thickness.

Project layout

busbar-designer/
├── app.py                 # Flask server: static files + /api/export/{step,dxf,svg}
├── busbar_export.py       # build123d → STEP / DXF / SVG
├── requirements.txt
├── scad_snippet.scad      # paste into hex_cell.scad to echo per-cell coordinates
├── CLAUDE.md              # architecture notes for Claude / future contributors
├── tests/
│   └── test_export.py
└── static/
    ├── index.html
    ├── styles.css
    └── js/
        ├── app.js
        ├── importer.js
        ├── viewport.js
        ├── groups.js
        ├── geometry.js
        └── exporter.js

Deploy to a home server

Recommended: manual LXC + install.sh

1. Create LXC in Proxmox web UI — Debian 12 standard template, unprivileged, 4 cores / 8 GB RAM / 32 GB disk, network DHCP. Enable Features → nesting=1.
2. Inside the LXC (pct enter <CTID> from the host):

   REPO_URL=https://gitea.example.com/me/busbar-designer.git \
   bash -c "$(curl -fsSL https://gitea.example.com/me/busbar-designer/raw/branch/main/deploy/install.sh)"
   

3. Open http://<lxc-ip>:5000 from any device on your LAN.

Update after git push to your Gitea:

pct exec <CTID> -- bash /opt/busbar-designer/deploy/update.sh

See deploy/README.md for backup/restore, troubleshooting, and what install.sh actually installs.

Alternative: Docker

git clone <repo> busbar-designer && cd busbar-designer
mkdir -p data
docker compose up -d --build

data/ is bind-mounted at /app/data so the SQLite DB survives docker compose down.

Reverse proxy (optional)

If you want it behind your existing nginx / Caddy / Traefik:

location / {
    proxy_pass         http://127.0.0.1:5000;
    proxy_set_header   Host $host;
    proxy_set_header   X-Forwarded-For $remote_addr;
    proxy_read_timeout 120s;   # STEP export can take a few seconds
    client_max_body_size 5m;
}

For Caddy:

busbar.example.com {
    reverse_proxy 127.0.0.1:5000
}

Security

The app has no authentication. Either:

• expose only on your LAN (default), or
• put it behind an authenticating reverse proxy (Caddy basic_auth, Authelia, Pocket-ID, etc.).

Troubleshooting

• pip install build123d fails on Windows / Python 3.13 — the prebuilt OCP wheels lag the latest Python release. If your python --version is 3.13, install Python 3.12 from python.org and use it for the venv: py -3.12 -m venv .venv.
• STEP opens empty in FreeCAD — make sure at least one busbar exists and contains ≥ 1 cell. The exporter writes only assigned busbars.
• Port 5000 in use — set PORT=5050 python app.py.

License

MIT.