Intro

This series of notes describes developing process of custom power bank.

Purpose: assemble power bank.

1 Battery Holder Soldering

First of all, since to all components are soldered I manually soldered two 3x 21700 holders on the bottom side, but since THT components has ~1mm pins I have to use any 1mm spacer (it could be removed after soldering)

2 Speaker

I used 3M glue to attach speaker to the board:

3 Nuts Insertion

Since I wasn't able to add also M5 nuts into 3DM order I have to buy it separately and insert them manually using soldering iron.

Tip: don't try to rotate nut, just slightly and slowly push by hot soldering iron tip.

• Part number: EMLU-M5-L6

Residuals I removed using drill and soldering iron.

4 Display Bracket + EVA

The display has metal shielding on the bottom side, which can easily short something on the board:

To fix this I cut EVA 1mm gasket to use it as isolator (but better to have also glue layer):

After that the display inserted into plastic bracket:

5 Diffusers

Since diffusers are made from transparent acrylic I additionally process them by sandpaper to make it matte, but in future I'll just order non-transparent acrylic.

Insertion is pretty easy and the result looks fine:

6 Top Cover

Install plastic caps (5 PCS) SC109AA1 onto the button on the board and place top acrylic cover according to the holes:

Screw cover using four long screws (M3x) and two short (M3x), it could be stainless steel or black.

I tried also 2mm top cover and it also works fine due to several support points (nuts + heatsink), but 3mm still better in case of direct blow.

• Part number: EDLG-S1-M3-L10
• Part number: EDLG-S1-M3-L16

7 Perimeter

I decided to not use this part because Nylon not appropriate for such think and long detail.

But here is an example of installation using two screws M3x and M3x.

Assembled Device

Additionally

The case has optional bottom handler for bike/bagpack.