Project Overview: Custom Power Bank PCB Development
This project came from a customer in India who contacted us through our website for power bank PCB design and manufacturing support. The customer planned to develop two types of power bank circuit boards. They provided an initial CAD drawing. Although the drawing required optimization, the mechanical dimensions were accurate, which helped speed up the PCB layout and structural matching process.
The main difference between the two versions was the display system: one design used 4 white LED indicators, while the other adopted an LCD display module. Other electrical and structural requirements were nearly the same.
Electrical Specifications and Functional Requirements
Version 1 – LED Indicator Power Bank PCB
- USB1 & USB2 Output: Quick Charge 3.0
- 4 White LED Power Indicators
- Micro USB Input: Quick Charge 3.0
- Over‑charging protection
- Deep discharge protection
- Overheating protection
- Overvoltage protection
- Push‑button control
- Efficiency: 95%
- 1‑year warranty design target
Version 2 – LCD Display Power Bank PCB
- USB1 & USB2 Output: Quick Charge 3.0
- 1 LCD Power Display
- Micro USB Input: Quick Charge 3.0
- Charging protection
- Deep discharge protection
- Overheating protection
- Overvoltage protection
- Push‑button control
- Efficiency: 95%
- 1‑year warranty design target
PCB Fabrication Requirements
Both power bank PCBs were designed under the same manufacturing standards:
- PCB Layers: 2‑Layer PCB
- Material: TG130
- Board Thickness: 1.6 mm
- Copper Thickness: 1 oz
- Surface Finish: HASL
- Solder Mask: Green
- Silkscreen: White
- Standard: IPC‑6012 Class 2
- Punch tooling hole tolerance: ±0.005
- Conductor width tolerance: ±20%
- UL approved fabrication
- Board Size: 35 mm × 100 mm
- Components mounted on both sides
Design Optimization and Mechanical Fit
Designing these two power bank circuit boards was efficient for our engineering team because we already have our own power bank brand, “Just One”, covering multiple capacities and housing structures. Our previous design experience helped shorten development time.
Our engineers first optimized the customer’s CAD drawing and created a compact PCB layout, especially for the version with the LCD module. We received three 3D‑printed housing samples from the customer and verified that the PCB matched the enclosure structure and mounting positions.
After finishing the layout, we sent the updated PCB design files to the customer for confirmation before sample production.
Rapid PCB Prototyping and Functional Testing
After approval, we started PCB prototyping and assembly. Each version had three samples produced. From PCB fabrication and component sourcing to final SMT and assembly, the full process took only 7 days.
We connected the boards to batteries and mobile phones for testing. The phones immediately showed charging status. Both input and output parameters met the Quick Charge specifications and protection requirements. Functional testing proved the design performance was stable.
Samples were shipped to the customer. After two days of testing, the customer confirmed satisfaction with both electrical performance and compact size. Since we had already provided an estimated mass production cost earlier, the project smoothly moved into volume manufacturing. The first order was 1,000 units for each model.
Panelization and PCB Assembly Process
Each PCB measured 35 × 100 mm. For production efficiency, we panelized them into 189 mm × 200 mm panels, with 10 pieces per panel. This made SMT assembly and handling easier.
Because the design required double‑sided assembly, special attention was paid to USB connectors and the LCD module.
USB Soldering Reliability
To prevent cold solder joints and connector lifting, we enlarged the PCB pad area under the USB connector by about 1 mm during design. This structural reinforcement improved solder joint reliability during reflow and handling.
LCD and Connector Soldering Control
The LCD connector used silver‑tin wire. Recommended soldering temperature was between 290°C and 310°C. During soldering, the LCD was held at approximately a 30° angle, while components such as microphones, motors, or speakers could be soldered at around 40°. Proper angle and heating control ensured both solder joints reached ideal temperature simultaneously.
Successful Mass Production Delivery
We also assisted the customer in verifying the housing fit during mass production. The first batch of 1,000 units was successfully completed and delivered on schedule. Stable PCB quality, reliable protection circuits, and strict assembly control ensured product consistency.
We believe that helping customers succeed is the foundation of long‑term cooperation. Every PCB project is a partnership aimed at achieving mutual growth.
Start Your Power Bank PCB Project With Us
If you are developing a power bank PCB, battery management PCB, or any custom consumer electronics circuit board, our engineering and manufacturing teams are ready to support you — from design optimization and prototyping to full mass production.
Contact us today to discuss your project requirements and receive a professional quotation. Let’s turn your idea into a reliable, manufacturable PCB product.
