I put a WiFi router into a phone charger (Final Post)

By Ryan Walker

After the compute boards were finished, I built and tested the power boards.

Fire Extinguisher not pictured

Newer readers may not be aware, but the power board stacks above the compute board as pictured below. The power board is responsible for converting mains to 5V and creating all the other voltage rails required by the central processor. The compute board houses the microprocessor, RAM, WiFi radios etc. For lots of details on the electrical design, you might find Part 1 interesting.

I then glued the contacts into the enclosure; these parts will be over-moulded during the injection moulding process in the final design. It’s essential these contacts are secure in the device; if they come off in an outlet, someone would get hurt. I wouldn’t trust my glue job for anything other than a prototype handles by myself alone.

The mains blade contacts interface to the PCB through friction fit contacts are shown below.

After six months, I finally have the prototype completed. I flashed the OS to the SD card, fired it up, and the UART logs looked fine. If you want more details about what I just said, part two has lots of details on building and configuring the OS.

Proto 1

I was planning on getting a crowdfunding campaign going, but the chip shortage ruined those plans for now (more on the chip shortage in part three). I don’t want to pivot over to other untested chips, so the crowdfunding will have to wait. I want to thank all the support I have received through the security and open source community.