NACS Emergency Release Device for V3 Superchargers

Introducing the NERD — NACS Emergency Release Device Inspired by expensive commercial designs, the NERD (NACS Emergency Release Device) is designed to provide some extra peace of mind without the expensive price tag.   The NERD is an automatic Tesla Supercharger release device that allows you to safely eject a V3 Tesla Supercharger handle from your vehicle. When you stop charging, the spring mechanism ejects both the NERD and the Supercharger handle away from the car, allowing you to drive away without having to return to the vehicle to remove the charging handle.   How to Use Place the NERD over the Supercharger handle, with the flat/spring side facing the vehicle. Press the Supercharger handle firmly into the charge port and hold it there for a second or two to ensure good contact. To release the Supercharger, simply press Stop Charging in the Tesla app or vehicle. The NERD will spring the Supercharger handle away from the vehicle and onto the ground. If you want to keep the NERD attached to your vehicle after driving away, add a lanyard, cord, or similar tether through the loop on the spring footing and attach or loop it around the charge port area. Materials 6 mm OD (outer diameter) compression spring, at least 140 mm long. I used this spring from Amazon and cut it to length with pliers. PETG filament or another strong, heat-resistant filament. How to Print and Assemble Print the NERD in PETG or another strong material that can tolerate elevated temperatures, since the device will likely be stored inside your vehicle. Supports are enabled for the bottom of the main body. No other supports are required. These should remove quite easily. Cut the compression spring into two approximately 70 mm sections. You can make the springs slightly longer if desired. Install each spring onto the spring peg on the bottom base. Apply downward pressure while twisting the spring to work it over the peg. Align the springs and base guides with the corresponding openings in the body. Push the base into the body until the base guides pop through the opposite side. The guides should catch on the body and hold the base securely in place. Before using the NERD with a vehicle, test the mechanism manually at a Supercharger to make sure the springs compress and release freely. Important Caveats Currently compatible with V3 Superchargers only. The NERD fits over a V4 Supercharger handle, but the current spring mechanism does not eject it. After experimenting with multiple versions, I was unable to get reliable V4 operation. If you are interested in modifying the design to work with V4 or other NACS connectors, I would love to see an updated version! Not compatible with Tesla Wall Connectors or Mobile Connectors. The NERD was designed specifically around the geometry of the V3 Supercharger handle. Vehicle compatibility: I have tested the NERD on a Model X. Based on the charge-port and Supercharger geometry, it should also work with the Model S, Model 3, and Model Y, but I have not personally tested it on all of these vehicles. Safety Test before using. Always test the NERD and verify that it operates correctly before using it with your vehicle or a Supercharger.   The NERD is a 3D-printed accessory and has not been tested or certified by Tesla. Use it at your own risk. Make sure the device is properly assembled and securely positioned before use. Always verify that the charging session has stopped before attempting to drive away.   I am not responsible for damage to the NERD, your vehicle, a Supercharger, the charging equipment, or the parking lot or surrounding property resulting from the use of this device.   The Supercharger handle is intentionally ejected toward the ground, so make sure there are no people, pets, vehicles, or other objects directly beneath or near the charging handle when releasing it. CAD Files I have also included the CAD files containing the various design iterations and variations I tested while developing the NERD. I am still a beginner when it comes to CAD and mechanical design, so the files may leave a lot to be desired. However, I hope they are useful to anyone who wants to remix, modify, or improve the design, particularly if you're interested in developing a version that works with V4 Superchargers.