Dual-Board Power & Distribution Design
Budget: $30 – $250 USD
Board Dimensions: Both boards must have the exact same footprint
Mounting: 4x M3 mounting holes in the corners, aligned perfectly between both boards for stacking with standoffs.
2. Board A: Power & Charging (The "Base")
Goal: A high-current power bank circuit to charge batteries and output 5V.
Controller: Use the IP5306 (Standard version) or a similar Power Bank SoC.
Battery Input: Surface Mount (SMT) Keystone 1042 dual 18650 holder.
Note: Batteries must be wired in parallel (1S2P).
Charging Input: USB-C (6-pin, Charging Only).
Requirement: Include 5.1kΩ resistors on CC1/CC2 lines so it works with USB-C to USB-C PD chargers.
Status Indicators: 4x LEDs to show battery level (25%,50%,75%,100%).
Power Output: One 2-pin JST-PH 2.0mm connector (Female) providing 5V.
Protection: Integrated over-charge, over-discharge, and short-circuit protection.
3. Board B: Distribution Board
Goal: To power 6 XIAO modules simultaneously with maximum stability.
Microcontrollers: 6x Seeed Studio XIAO ESP32-C5 footprints.
Mounting Style: Use Castellated Pads for surface mounting.
Physical Stability: All XIAO pins should have SMD pads for soldering/stability, even if they aren't electrically connected to anything.
Power Input: One 2-pin JST-PH 2.0mm connector (Male/Header) to receive 5V from Board A.
Routing Logic: * All 5V pins on the XIAOs must be connected to a shared high-current power rail (minimum 60 mil trace width).
All GND pins connected to a shared ground plane.
Stability: Add a 100µF to 220µF electrolytic capacitor (SMT or through-hole) at the JST power input to handle Wi-Fi 6 current spikes.
Mounting: 4x M3 mounting holes in the corners, aligned perfectly between both boards for stacking with standoffs.
2. Board A: Power & Charging (The "Base")
Goal: A high-current power bank circuit to charge batteries and output 5V.
Controller: Use the IP5306 (Standard version) or a similar Power Bank SoC.
Battery Input: Surface Mount (SMT) Keystone 1042 dual 18650 holder.
Note: Batteries must be wired in parallel (1S2P).
Charging Input: USB-C (6-pin, Charging Only).
Requirement: Include 5.1kΩ resistors on CC1/CC2 lines so it works with USB-C to USB-C PD chargers.
Status Indicators: 4x LEDs to show battery level (25%,50%,75%,100%).
Power Output: One 2-pin JST-PH 2.0mm connector (Female) providing 5V.
Protection: Integrated over-charge, over-discharge, and short-circuit protection.
3. Board B: Distribution Board
Goal: To power 6 XIAO modules simultaneously with maximum stability.
Microcontrollers: 6x Seeed Studio XIAO ESP32-C5 footprints.
Mounting Style: Use Castellated Pads for surface mounting.
Physical Stability: All XIAO pins should have SMD pads for soldering/stability, even if they aren't electrically connected to anything.
Power Input: One 2-pin JST-PH 2.0mm connector (Male/Header) to receive 5V from Board A.
Routing Logic: * All 5V pins on the XIAOs must be connected to a shared high-current power rail (minimum 60 mil trace width).
All GND pins connected to a shared ground plane.
Stability: Add a 100µF to 220µF electrolytic capacitor (SMT or through-hole) at the JST power input to handle Wi-Fi 6 current spikes.