Design and Build a Portable USB Charger




About: I always liked making stuff and when my grandfather showed me Instructables I became an addict. I don't have any degrees yet but I'm working on my aeronautics engineering degree :-P

In this guide i will show you how to design and build a portable USB charger.

Lets start..

Step 1: Materials

What you'll need:

1) Project enclosure: 3.34"L x 1.96"W x 0.83"H.

2) USB 0.9V-5V to 5V DC Boost Step-up Power Supply Module.

3) 5V Micro USB 1A Lithium Battery Charging Board Charger Module.

4) Wires.

5) Battery holder 3XAAA.

6) Duct tape.

7) Shrinking isolation tube.

8) Hot glue gun.

9) Spray color (Black and Varnish).

10) Switch.

11) s

Step 2: Designing the Box

First, spray the box with black, I recommend spraying a few layers.

I decided to print comic and to glue it on the top of the box but you can put there anything you want..

I printed my favorite comic and i used a pencil to mark the box's size.

After that i cut the comic to the size of the borders (pic No.4) and glued it on.

Later on i removed all of the plastic pins inside the box (use pliers).

Now mar on each side of the box the size of our USB and mini USB connections.

Cut holes where you marked, start by making a small hole in each corner, use a file tool to make the hole prettier.

Step 3: The Inside Parts

Start by soldering wires to the modules, wrap each of them with duct tape and glue each one in its hole.

Now insert the battery holder (if its too big use sand paper to make it a bit smaller so it could fit your box).

Now there are two options:

1) Recommended- solder the positive wires of the mini USB module and the wires of the battery holder together, than solder the positive wires to a switch and to it solder the USB module wires. Solder all the negative wires together (the switch will turn of and on your charger).

2) Solder all of the positive wires together and all the negative ones together.

Last thing: insert rechargeable batteries and you're finished!!

A great benefit of this charger is that if your rechargeable batteries are empty you can insert normal ones and use them to charge your phone.

Please leave any comments notes or questions I will be glad to answer them. Please also vote for this instructable on the epilog, green design and home design contests.

Step 4: That's It

I hope you enjoyed this guide, if you have any questions I will answer them happily.

Like this project? Check out my profile, my Facebook page and my YouTube Channel.



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    7 Discussions


    4 years ago on Step 3

    Do you know if it's OK to use more batteries? I was thinking up to 10 so it can charge a tablet too...but whether to connect them in parallel or series?

    3 replies

    Reply 4 years ago on Step 3

    As far as electronics go, you can give it too much voltage. Each battery contains 1.2 volts, and in series ten would create 12 volts. For best charging of usb devices you should have 4.2V - 5V. The amount of charge you can get from each battery comes in from the mA. If you put more batteries than necessary in, you will get a higher mA count, just also be sure to regulate your voltage so you don't fry your phone. Hope I helped!


    Reply 4 years ago

    Tnx for your comment, the charger wont fry your phone, it outputs 5V because of the use of the module I used that outputs 5V.


    Reply 4 years ago

    I suppose its should be ok to add batteries in a series according to the limit of the usb charger module, my module max voltage input is 5 so I can add only one more AA battery, but in parallel there's should not be a problem adding batteries.


    4 years ago on Introduction

    Hi Crashzoom,

    this is a great little project, really like it. I have a question, and please forgive my

    naivety, but am I right that you can recharge the AAA NiMH batteries through the

    5V Micro USB 1A Lithium Battery Charging Board Charger Module, or am I having a "Blonde" moment?! - No offence intended to blonde folk (-:

    I fancy building one myself - Cheers (-:

    2 replies

    Reply 4 years ago

    Hi, first thanks for your comment. I suppose the module can charge NiMH batteries but I think it won't charge them as well as the Li ones therefore is suggest using lithium batteries.