"VOLTMASTER" the 5V Power Source

Greetings everyone and welcome back, and here's something powerful.

Voltmaster is a DIY battery pack made completely from scratch and can provide constant 5V to power all sorts of electronics devices or microcontroller setups.

In order to charge and discharge the battery pack, we have used nine 3.7V 2900mAh Li-ion cells that are all connected in parallel with a custom power management circuit. This circuit produces a stable 5V output that is connected to two banana pin sockets so that we can add banana pins to use the 5V to power a variety of 5V electronics, such as a Raspberry Pi Pico setup or another similar device.

This enclosure was created with a cyberpunk concept, and a few sections were also printed in two colors using different filaments.

This battery pack setup has four fuel level indicators that indicate the battery power percentages of 25%, 50%, 75%, and 100%. The user can charge the device using the Type C port on the back of the device using a smartphone charger.

This article is about the full build process of this project, so let's get started with the build.

These are the materials used in this project.

1. Custom PCBs
2. IP5306 Power Management IC
3. 10uF 1206 Capacitors
4. 5.6uH Inductor SMD
5. Type C Port THT
6. Push Button
7. 2R 1206 Resistor
8. 10k 1206 Resistor
9. Banana Pin Socket
10. Banana Pin Connector
11. 3D Printed Parts
12. Li-ion Cells 3.7V 2900mAH

The three primary sections of the Voltmaster model are the following:

The circuit is held in place by the top section, which also has the power ON/OFF switch, indication LEDs, and 5V output banana pin socket.

The lithium cell is held in place by the bottom and middle sections.

The first thing to be modeled was the circuit, which has four LEDs positioned close to the edge, a USB type C port on one side, and a switch in the middle.

The lithium cell battery pack, which was made up of nine cells set up in a grid, was then prepared.

The battery pack served as the centerpiece of the model, and the circuit was modeled in the top section that houses the circuit and connects to the midsection. The battery is added to the midsection from the bottom, and the bottom lid closes the battery's entry point, thus locking it in place.

Additionally, we added three flat parts that attach to the front, left, and right faces of the midbody to enhance the setup's aesthetics and give it a subtle cyberpunk vibe. We have added a few patterns and designs to these flat sections to fit the cyberpunk style. Superglue will be used to attach these flat sections to the midsection.

We used the STL files that we had exported once the model was finished to 3D print the top and bottom sections in black PLA, the midsection and SWTCH in orange PLA, and the flat pieces in dual-color, black and white PLA.

There was also an accent part for the top section, which was 3D printed in orange PLA.

Every part had the same set of settings; we utilized a 0.4mm nozzle, 20% infill, and a 0.2mm layer height.

We prepared the schematic in which we used the IP5306 IC Setup, a power management IC that can provide stable 5V 2.4A with a 3.7V Li-ion Cell, to power the XIAO and the LEDs. Furthermore, this IC offers charging functions, such as a battery fuel indicator and charging cutoffs (low- and high-cut).

The push button included in the IP5306 setup can be used to turn the device ON or OFF in this instance. To indicate battery fuel, 3mm through-hole LEDs were installed. We have also utilized a through-hole Type C port, which has just the VCC and GND pins.

We wired the IP5306's output to a CON1 Pad, which will subsequently be linked to a banana pin socket in order to output 5V.

Following the preparation of the schematic, we created the board design, by referring to the previously created PCB model. Using the model dimensions, we created the board's shape and positioned the LEDs, push button, and Type C port in accordance with the PCB model.

After completing the PCB design, we export the Gerber data and send it to HQ NextPCB for samples.

An order was placed for Green Solder Mask Board with White Silkscreen.

After placing the order, the PCBs were received within a week, and the PCB quality was pretty great.

In addition, I have to bring in HQDFM to you, which helped me a lot through many projects. Huaqiu’s in-house engineers developed the free Design for Manufacturing software, HQDFM, revolutionizing how PCB designers visualize and verify their designs.

Also, NextPCB has its own Gerber Viewer and DFM analysis software.

Your designs are improved by their HQDFM software (DFM) services. Since I find it annoying to have to wait around for DFM reports from manufacturers, HQDFM is the most efficient method for performing a pre-event self-check.

Here is what online Gerber Viewer shows me. Would not be more clear. However, for full function, like DFM analysis for PCBA, you, need to download the software. The online version only provides a simple PCB DFM report.

With comprehensive Design for Manufacture (DFM) analysis features, HQDFM is a free, sophisticated online PCB Gerber file viewer.

It provides insights into advanced manufacturing by utilizing over 15 years of industry expertise. You guys can check out HQ NextPCB if you want great PCB service at an affordable rate.

1. We started the circuit assembly process by first adding solder paste to each component pad one by one using a solder paste dispensing needle.
2. Next, we pick and place all the SMD components in their location using an ESD Tweezer.
3. Soldering the SMD components requires the use of a reflow hotplate. The solder paste melts and all components connect to their pads when the board achieves the temperature reached by the reflow process, which essentially heats the circuit from below. Here, we are utilizing the brand-new MINIWARE MHP50 reflow hotplate.
4. The push button, Type C port, and 3 mm green LEDs were subsequently put into the board's through-hole components, which were all located on the upper side of the board. Next, we use a soldering iron to solder their pads from the bottom side.

This project's power supply is a battery pack made up of nine 3.7V 2900mAh Li-ion cells linked in parallel. The total capacity of the pack is 3.7V 26100mAh (2900x9), which greatly increases the setup's overall backup.

In order to build this battery pack, we attach the positive and negative of every cell together to form a parallel connection. We do this by using nickel-plated steel strips. In order to complete this operation, we appointed a tigwelder for lithium-ion cells, which is done in a professional battery pack manufacturing facility. We received assistance from a nearby battery pack factory, which performed the tig welding.

Why not solder the battery pack directly instead of using the Tig welding process?

For one simple reason—the heat from the soldering iron can harm the battery, causing it to burst, leak, catch fire, or explode—soldering directly to lithium-ion cells can be risky. In order to prevent them, we should always utilize nickel strips and tig weld them instead of soldering any wire or metal strip directly to the lithium cell's components.

1. We began assembling the bottom section assembly with the battery pack and midsection by first putting the battery pack inside the body of the midsection. We make sure to add the wire through the midsection grids so later we can easily solder them with the circuit.
2. The battery pack is then secured in place by connecting the bottom piece to the midsection. Four M2 screws are then added to permanently fasten the two sections together.

1. Using super glue, we first attached the top accent piece to the top section to begin the assembly process.
2. Next, we unscrew the nut on each banana pin and tighten them on the top section body to position the positive and negative banana pin sockets in their proper locations.

1. Wires are added to the 5V and GND terminals to begin the TOP Section and Circuit Assembly procedure.
2. The positive and negative banana pin sockets are then connected to these 5V and GND wires.
3. After positioning the 3D printed switch knob, we inserted the wiring and fastened it with four M2 screws to the top section.

1. We begin the final assembly procedure by using a soldering iron to connect the battery pack's positive and negative terminals to the circuit's battery connectors.
2. The top assembly section was then placed on top of the midsection, and four M2 screws were used to fasten them both.
3. We used super glue to add the flat components to the front, left, and right of the midsection after fastening the three sections together.
4. The assembly is now finished.

This is the result of this powerful build: a cyberpunk-themed battery pack that can supply a steady 5V/2A to power a variety of 5V devices. This battery has a 96.5Wh overall capacity, which is excellent for long-term use to power anything.

To turn this device on, press the center push button. If you press the button twice, it will switch off. After 30 seconds, it will automatically switch off if there is no load connected.

This battery pack can be charged using the type C port that is located on the back face of the top section. An indicator that indicates the battery's charge level will be provided by the battery indicator LEDs as it charges.

We used a multimeter to measure the output of this device to make sure it was operational, and sure enough, it delivered a steady 5V and was operating as intended.

Next, in order to power the Raspberry Pi Pico Setup, we connected a WS2812B LED to the Pico's GPIO0, VCC, and GND using our Voltmaster Battery Pack.

We powered the Pico setup by adding 5V to its VBus terminal and GND to GND. This showed that the battery pack device functions and can be used to power various microelectronic setups that need a steady 5V to run.

Overall, this project was completed and needed no further revisions.

Special thanks to HQ NextPCB for providing components that I've used in this project, check them out for getting all sorts of PCB or PCBA-related services for less cost.

Thanks for reaching this far, and I will be back with a new project soon.