Cloning a Sennheiser BA2015 battery pack

A hobbyist has shown how to create a working clone of the Sennheiser BA2015 battery pack using readily available components and DIY methods, potentially lowering costs for users of wireless microphones.

The original Sennheiser BA2015 battery pack is an expensive, proprietary component used in many wireless microphones. It contains two NiMH cells, a small NTC temperature sensor, and a battery management system designed to prevent charging non-rechargeable batteries. The enthusiast tore down an original pack, analyzed its internal components, and designed a replacement using off-the-shelf cells and a custom 3D-printed case.

The replacement involves two Panasonic cells, a small NTC resistor, and a custom-built case that mimics the original dimensions. The process required destructive disassembly of the original pack, understanding of the internal wiring, and careful reconstruction to ensure compatibility with the microphone’s charging system. The builder also incorporated a simple mechanical switch to simulate the original detection contact, allowing the new pack to be recognized correctly by the microphone’s charger.

Implications for Wireless Microphone Users and DIY Repair

This project demonstrates that the high cost of proprietary battery packs like the BA2015 can be bypassed with DIY solutions, potentially saving users hundreds of dollars. It also highlights the possibility of extending the lifespan of older equipment through custom replacements. For more on repair options, see our article on Sennheiser battery replacements.

Background on Sennheiser BA2015 Battery Packs and Market Trends

The Sennheiser BA2015 battery pack is widely used in wireless microphones, valued for its integrated protection circuitry and rechargeable NiMH cells. Officially, it costs between $80 and $100, making it one of the more expensive AA-sized battery solutions. Many third-party replacements are available at lower prices, often with simpler designs using generic cells. The original design includes a small NTC sensor and a detection contact that prevents charging non-rechargeable batteries, which complicates DIY cloning efforts.

In recent years, hobbyists and repair enthusiasts have increasingly explored reverse-engineering proprietary electronics to reduce costs and improve repairability. This case adds to that trend, showing that with enough technical skill, the internal components and design principles of such packs can be replicated at a fraction of the cost.

“The only real reason for these things to exist is to avoid the charging of non-rechargeable batteries, but that doesn’t justify the high price. Third-party options are much cheaper and easier to replace.”

— Hacker News user

“By analyzing the internal structure and using common components, I managed to create a functional clone that works seamlessly with the microphone’s charging system.”

— DIY builder

Long-term Reliability and Safety of Homemade Clones

It is not yet clear how durable or safe these DIY clones are over extended use. The original packs include specific circuitry and protection features that may not be fully replicated, raising concerns about potential damage to microphones or safety hazards. The long-term compatibility with official chargers and warranties remains unverified.

Next Steps for DIY Enthusiasts and Manufacturers

Further testing is needed to evaluate the longevity and safety of these clones. Enthusiasts may attempt to produce batch replacements, while manufacturers could consider offering official, affordable alternatives or open-source designs. Learn more about Sennheiser battery pack options.

Key Questions

Can I safely use a DIY cloned battery pack in my Sennheiser microphone?

While the clone has been demonstrated to work, safety and reliability are not guaranteed. Use at your own risk, and consider potential warranty or safety issues.

Will this clone work with all Sennheiser BA2015-compatible microphones?

The clone is designed based on typical internal configurations; however, compatibility may vary depending on the specific model and internal circuitry.

Does building a clone void my warranty or violate any regulations?

Creating and using DIY replacements may void warranties and could have legal or safety implications depending on local regulations and use cases.

How much would it cost to build a batch of these clones?

Material costs for parts are estimated at under $5 per pack, depending on sourcing, significantly cheaper than official replacements.

Is this project technically difficult for an average hobbyist?

Yes, it requires skills in electronics, disassembly, and 3D printing. It is not recommended for beginners without prior DIY experience.

Source: Hacker News