box for lithium ion battery

I need a design for a lithium ion battery box. The box should not be tamper resistant or only able to be opened by an authorized person.. The purpose is to preserve a warranty and longevity of battery. If the box is opened by unauthorized person then the warranty is void. If a tech opens the box he should be able to close it again with some pin that we three D print and that can not be duplicated. alternatively, we can just break off one side of the box and reprint that to close it. The idea for production is that we do the first 100 from a place like shapeway then maybe print the broken side, or the replacement pin locally.

We would need space for a 4 or 5 USB connectors and one for a cigarette lighter for charging the unit. Thats about it. Snap it shut, and move on. The material should be strong enough to be carried around. Think in a sac on the side of a donkey or on someones head.

When a tech goes to charge it or repair it, he should break the seal himself and replace it when he is done.

ANY ADDITIONAL GUIDANCE LIKE DESIGN OR DESIGNER SUGGESTIONS, Good and inexpensive manufactures/3d print shops would be greatly suggested.

Thank you.

A simple way to do an anti-tamper device would be like this.
As long as the material you select is slightly springy, this acts as a one-way closure.

That's great Stonysmith. Thanks. So how you open the enclosure when you want to get inside?

You could make a key similar to the green part here. If the distance from the bottom up to the locking mechanism is long enough, then the odds of them using a screwdriver to open it are reduced.

FYI.. this crosssection was to give you an idea of the concept only.. for more security, place the locking mechanism(s) on all four walls, and possibly even a pair of them per wall.

Please note: this design is NOT original. If you are making a commercial product, there is a strong chance that this is covered by some patent somewhere, and you'd need to seek the rights to use it.

Can something like this be 3d printed at low cost?

Yes, it can be 3d printed. The cost will be completely a function of the size.
A 2" cube would run about $16, but an 8" cube would run $250

You can play around with various sizes here:
http://www.stonysmith.com/wired/VolumeEstimator.asp?L=50&amp ;W=50&H=50&T=.7

This is helpful. So after the $35 prototype, is there a known place to print them to bring the cost down if you are making 1000 of them?

Not sure if you'll find anywhere cheaper to print, but if you're looking at 1000+ units you really ought to be looking at injection-moulded plastic. The tooling cost up-front might be high, but then they are pennies per unit to squirt out thereafter. But before you fork out $10-$20k on steel tooling, do get a prototype of your design printed here first at only tens of dollars to make sure it's a good design! After all, that's why they still call this "rapid prototyping"...