Case for PD100W Fast Charging Module

Enclosure for DC 5.5x2.1mm Input Version

This is a custom-designed, two-part protective case for the high-power PD100W Fast Charging Module commonly found on Temu and AliExpress. It is specifically engineered to house the version featuring a DC 5.5x2.1mm input jack, providing a secure and professional enclosure for your DIY power setup.

🛠 Assembly & Hardware

The case features a snap-fit design that locks the board inside, making screws optional but recommended for extra security.

* Screws: Recommended hardware includes 2mm self-tapping screws or standard M2 screws (6–12mm length).

Tip:* Depending on your print tolerances, you may want to use a small drill bit to clear the fixing holes for a perfect fit.

* Tool-less Alternative: If you don't have screws, the holes are sized to accept a short piece of 1.75mm 3D printing filament as a pin to secure the board and case together. Use some glue to secure the pin.

🖨 Printing Tips

Since this 100W module can generate heat during sustained power delivery, material choice is important. Although the casing is designed to have minimal contact with the board only on the edges, and the casing is well ventilated, PLA is known to soften on higher temperatures.

* Material: PETG, ABS, or ASA are recommended for better heat resistance. Standard PLA may soften under high loads.

* Orientation: Print the flat faces of both parts against the build plate for the best surface finish and to eliminate the need for supports.

* Infill: 20% or higher for structural rigidity, especially around the screw holes.

* Tested Settings: A successful print was achieved using Verbatim ABS-55026 at 0.16mm resolution.

📂 Design Files

The enclosure consists of two distinct parts, available via Tinkercad:

1. pd100wcase1b: The base/back section.

2. pd100wcase1f: The front/top cover.

🛒 Hardware Sources

If you haven't purchased the charging module yet, it can be found at the following retailers:

* AliExpress - PD100W Module

* Temu - PD100W Module