USB Charger Prototype
This 9V emergency USB charger is designed to work with iOS devices, with the internal PCB meeting Apple's MFi specification. I fabricated this accurate prototype entirely by hand in 15 hours using vacuum forming, soldering and other plastic shaping tools available in Bournemouth University’s workshops.
The split lines you see on the charger are by design to emulate the appearance of an injection moulded product mass-manufactured in two parts.
Accurate soldering and PCB design is essential when fitting internal components such as the battery — as well as lining up USB and on/off switch with the slots in the case.
The USB charger can charge iPhone and iPad. Given a fully charged 9V battery, it can give approximately 30% charge to an iPhone 6. In an emergency situation, this could make all the difference.
Fabricating to Tolerances
Creating a prototype as accurately as possible was the purpose of this project. The following images show the step-by-step process I followed during workshop sessions to produce an accurate product.
(Tap to enlarge)