TL;DR
A hobbyist has demonstrated how to clone and rebuild the Sennheiser BA2015 battery pack using readily available components. This development enables cheaper replacements and DIY repairs, but raises questions about authenticity and compatibility.
A hobbyist has successfully disassembled and recreated the Sennheiser BA2015 battery pack, demonstrating how to produce a functional clone using off-the-shelf components. This could enable cheaper replacements for users but raises questions about authenticity and device compatibility.
The original BA2015 battery pack contains two NiMH cells, a small NTC temperature sensor, and a battery management circuit, primarily designed to prevent the use of non-rechargeable batteries. The user tore down an authentic pack, modeled its dimensions, and built a replica using two Panasonic cells available at low cost. The process involved destructive opening of the original case, identifying the wiring and sensor placement, and designing a new case compatible with the existing microphone and charger system.
The key innovation was replicating the sensor and wiring configuration, including the third contact used to detect the battery type. The user replaced the original cells with two flat-top NiMH cells, soldered the necessary connections, and incorporated a similar NTC sensor. The new case was 3D printed with modifications to improve durability and fit, including rotating the print orientation to reduce layer stress. The process demonstrated that the core components could be sourced cheaply, significantly reducing the cost of replacement packs.
Implications for DIY Replacement and Cost Reduction
This development could significantly lower the cost of replacing Sennheiser BA2015 battery packs, which are often expensive and proprietary. By enabling users to build their own replacements with readily available parts, it may extend the lifespan of wireless microphones and reduce electronic waste. However, it also raises concerns about warranty voidance, device safety, and potential compatibility issues with official charging docks or firmware checks.
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Background on Sennheiser BA2015 Battery Pack Design
The Sennheiser BA2015 battery pack is a common component for many wireless microphones, containing two NiMH cells, an NTC temperature sensor, and a battery management circuit. Official replacements are costly, often priced between $80 and $100, and are designed to prevent use of non-rechargeable batteries. Third-party replacements exist but vary in quality, and DIY approaches have been limited by the complexity of the internal wiring and case design. The recent detailed teardown and rebuild demonstrate that the core components are accessible and modifiable, challenging the proprietary nature of the original design.
“This is how I tore down and rebuilt the BA2015 pack using cheap parts, making it possible to DIY a replacement.”
— Hacker News user
“Replacing the cells with affordable Panasonic NiMH cells and mimicking the sensor setup can drastically cut costs.”
— Electronics hobbyist
AMZZN 12PCS 1.2V 1800mAh Ni-MH AA Rechargeable Battery for Wireless Microphones, Electric Toys, Remote Mice, Calculators, Razors, Keyboards (12PCS Battery)
※ Dimensions: 50mm high (1.97inch), 14mm diameter (0.55inch), 1.2V 1800mAh AA Ni-MH rechargeable battery, including 12X1.2V Ni-MH AA…
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Remaining Compatibility and Safety Concerns
It is not yet clear whether the cloned battery pack will fully interface with Sennheiser’s official charging systems or firmware protections. There are also questions about long-term reliability and safety, given the use of homemade wiring and components. Additionally, legal and warranty implications of such DIY replacements are still uncertain.
YIBEICO 4-Pack Replacement Battery Cover for Shure BLX2/SM58,Beta58,PG58 Wireless Microphone to Repair The Broken Part (4PCS)
CUSTOM FIT:YIBEICO 4-Pack Replacement Battery Cover for Shure BLX2/SM58,Beta58,PG58 ,Please confirm your model before purchasing to avoid incompatibility
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Next Steps in DIY Battery Pack Replication
Further testing is needed to verify compatibility with Sennheiser microphones and chargers. Manufacturers or third-party suppliers may develop more refined kits or instructions based on this teardown. Users interested in DIY replacements should exercise caution regarding safety and warranty issues, and monitor ongoing developments for potential official or community-supported solutions.
AGPTEK Carrying Case, EVA Zipper Carrying Hard Case Cover for MP3 Players
LARGER STORAGE SPACE: The internal structure was optimized to increase the capacity. Suitable for storing most brands and…
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Key Questions
Can I safely replace my Sennheiser BA2015 battery pack with a DIY clone?
While technically feasible, DIY replacements carry risks related to safety, device compatibility, and warranty voidance. Proceed with caution and ensure proper handling of electrical components.
Will this clone work with all Sennheiser wireless microphone models?
Compatibility has not been fully tested across all models. The clone mimics the original’s electrical and physical design, but firmware or charging system restrictions may vary.
Is it legal to build and use a cloned battery pack?
Legality depends on local regulations and whether the device is used in commercial or personal contexts. There are no specific laws against DIY repairs, but warranty and safety considerations apply.
How much could I save by building my own BA2015 battery pack?
Using off-the-shelf NiMH cells and 3D printed cases, the cost could be reduced to under $10 per pack, compared to official prices of $80–$100.
Source: Hacker News
