This page provides 3D printable enclosures, accessories, and project ideas for your Li-Ion Boost Charger board.
⚠️ Safety First: All enclosures and projects involving this board must follow Safety Guidelines. Lithium-ion batteries require proper ventilation and protection.
Description: Ventilated enclosure for safe operation with integrated battery and boost converter.
Safety Features:
- Ventilation slots for heat dissipation
- Battery compartment with fire-resistant barrier
- Access to USB-C port
- LED visibility windows
- Emergency disconnect access
Features:
- Mounting posts for board (H1, H2 holes)
- Labeled connector access
- Switch access (customizable for SW4/SW5 or SW2/SW3)
- Test point access window
- TODO: Add 3D model files
Files:
Print Settings:
- Material: PETG or ABS (fire-resistant preferred)
- Layer Height: 0.2mm
- Infill: 30% minimum for strength
- Supports: TODO (Yes/No)
- Print Time: ~TODO hours
Assembly:
- TODO: Print all parts
- TODO: Install board using mounting holes
- TODO: Route wiring through channels
- TODO: Secure with screws/snaps
Safety Notes:
- Do not fully seal - ventilation is critical
- Use fire-resistant materials if possible
- Include warning labels
- Test without battery first
Description: Complete power bank housing with integrated battery holder and protection.
Features:
- Battery compartment with retention
- USB-C port access
- Output connector access
- Power switch access (customizable)
- LED status visibility
- Mounting points for strap/clip
- TODO: Add details
Files:
Print Settings:
- Material: PETG or ABS (strength and heat resistance)
- Infill: 40% for structural integrity
- TODO: Additional settings
Safety Notes:
- Include ventilation
- Battery must be secure and protected
- Include capacity label
- Follow transport regulations
Description: Fixed wall mount for charging station applications.
Features:
- Wall mounting bracket
- Organized cable management
- Access to all connectors
- Heat dissipation vents
- TODO: Add details
Files:
¶ Test/Development Stand
Description: Open-frame stand for testing and development with easy access to test points.
Features:
- Angled board mount
- Test point accessibility
- Connector labels
- Non-conductive mounting
- TODO: Add details
Files:
Difficulty: Beginner
Build Time: TODO hours
Description:
Create a portable USB power bank with 5V output capability.
Required Additional Components:
- 3D printed enclosure (see above)
- Li-ion battery (18650 or similar, TODO mAh)
- USB-C cable for charging
- Output cable with USB-A connector
- Battery holder (if not integrated in enclosure)
- TODO: Additional items
Build Instructions:
- TODO: Print enclosure parts
- TODO: Install board using mounting holes H1, H2
- TODO: Connect battery to J3 (BAT+) - VERIFY POLARITY
- TODO: Connect output cable to J1 (PWR_OUT)
- TODO: Route USB-C cable to J2
- TODO: Test all connections without battery
- TODO: Connect battery and test charging
- TODO: Final assembly and labeling
Safety Checklist:
Photos:
Difficulty: Intermediate
Build Time: TODO hours
Description:
Outdoor charging station with solar panel input and weather-resistant enclosure.
Required Additional Components:
- Solar panel (5V or 6V, TODO watts)
- Weather-resistant enclosure
- Charge controller (if solar voltage >5V)
- Li-ion battery with appropriate capacity
- Weatherproof connectors
- TODO: Additional items
Build Instructions:
Safety Notes:
- Waterproofing is critical
- Protect battery from temperature extremes
- Include overvoltage protection
Difficulty: Advanced
Build Time: TODO hours
Description:
Simple UPS for low-power devices like Raspberry Pi or network equipment.
Required Additional Components:
- Automatic switchover circuit
- Input power supply (5V)
- Li-ion battery pack
- Output voltage monitoring
- Status indicators
- TODO: Additional items
Build Instructions:
Note: This project requires additional circuitry for seamless power switching.
Difficulty: Beginner
Build Time: TODO hours
Description:
Compact emergency phone charger with indicator lights.
Required Additional Components:
- Small enclosure
- Li-ion battery (TODO capacity for phone charging)
- Short USB-A output cable
- TODO: Additional items
Build Instructions:
Difficulty: Intermediate
Build Time: Varies
Description:
Add rechargeable battery power to existing 5V USB devices.
Applications:
- LED light strips
- Small fans
- USB speakers
- Portable monitors
- TODO: Other devices
Build Instructions:
Safety Notes:
- Verify device operates safely on battery power
- Monitor current draw (must be < TODO mA)
- Include fusing if appropriate
Have you created a custom enclosure or project? Share it in the Gallery or submit to UnderBaked!
When designing custom enclosures for the Li-Ion Boost Charger:
- Board Size: TODO mm x TODO mm x TODO mm (with components)
- Mounting Holes: H1 and H2 (TODO mm diameter, TODO mm spacing)
- Clearance Needed: TODO mm on all sides for components
- Height Clearance: TODO mm (inductor L1 is tallest component)
Ventilation (MANDATORY):
- Minimum TODO cm² ventilation area
- Air flow around inductor L1 and boost IC U3
- Battery compartment must be ventilated
- Never fully seal the enclosure
Connector Access:
- J1 (PWR_OUT): Output connector location
- J2 (USB-C): Charging port - ensure cable clearance
- J3 (BAT+): Battery connector - Critical polarity marking
- J5 (PWR_IN): Alternative power input
- J7 (Vb): Battery voltage output
Switch Access (if populated):
- SW4, SW5 (top surface mount) OR
- SW2, SW3 (bottom through-hole)
- Configuration varies by order - verify your board
LED Visibility:
- LED1, D1, D2: Ensure clear viewing windows
- Consider light pipes for better visibility
Test Point Access:
- Optional access window for Vcc, GND, Vb test points
- Useful for troubleshooting and monitoring
Components That Generate Heat:
- Inductor L1: Warm under load
- Boost IC U3: Can get warm with high current
- Battery: Should remain cool (<40°C)
Cooling Recommendations:
- Airflow around L1 and U3
- Thermal contact with enclosure (if metal)
- Heat sink pads for U3 (optional, for high-current use)
- Keep battery thermally isolated from hot components
Enclosure Materials:
- PETG: Good heat resistance, stronger than PLA
- ABS: High strength, heat resistant, good for functional enclosures
- ASA: UV resistant, outdoor use
- Polycarbonate: Fire resistant, impact resistant (best for battery safety)
- Avoid PLA: Low heat resistance, not suitable for enclosed battery applications
Fire Safety:
- Consider fire-retardant filaments (V0 rated)
- Include fire-resistant barrier between battery and electronics
- Never use highly flammable materials near battery
¶ Safety Labels and Markings
Include on enclosure:
- Battery type and capacity
- Input/output voltage ratings (5V)
- Polarity markings for battery connection
- Warning: Contains lithium-ion battery
- Emergency disconnect instructions
- Ventilation warnings ("Do not block vents")
Download the board STEP file for accurate enclosure design:
Important: Model includes:
- Board outline
- Component heights
- Mounting hole locations (H1, H2)
- Connector positions
- Free: FreeCAD, Tinkercad, Fusion 360 (personal use)
- Paid: SolidWorks, Autodesk Inventor
- Free: Cura, PrusaSlicer, Slic3r
- Paid: Simplify3D
Before printing:
- Check component clearances
- Verify ventilation paths
- Confirm mounting hole alignment
- Test fit with non-powered board if possible
Created an awesome enclosure or project? We'd love to feature it!
Submission Guidelines:
- Include STL/STEP files
- Provide print settings and materials used
- Include safety considerations in design
- Provide assembly photos and instructions
- Document any modifications to board or circuit
- Submit via Contact
Safety Requirements for Submissions:
- Must include adequate ventilation
- Must provide battery protection
- Must include safety labeling
- Must follow Safety Guidelines
All official UnderBaked 3D models are provided under [TODO: License] for personal and educational use.
⚠️ You are responsible for the safe design and operation of your project. Lithium-ion batteries can be dangerous if improperly housed or handled. Follow all safety guidelines and local regulations.
Last Updated: May 25, 2026
Revision: Rev 2 Compatible