100W USB Type-C Power Delivery Source: Getting Started

RE: 100W USB Type-C Power Delivery Source: Getting Started

Canto26 — Wed, 11 Feb 2026 22:40:02 GMT

I've been wanting to build something just like this for my RV! Did you run into any issues with this design?

RE: 100W USB Type-C Power Delivery Source: Getting Started

shabaz — Thu, 15 Dec 2022 05:19:17 GMT

Really impressed with KiCad. It's possible to export the 3D file, and then import it into FreeCAD.

I wanted to see what would happen if two boards were inserted, and I tried that, and could see that the large electrolytic would clash with the DC input connector, if the boards were placed face-to-face.

It was hard though, because I can barely use FreeCAD. I had little idea what I was doing. It seems to be quite a difficult application to learn without any tutorial/video.

(Anyway, I'm not going to spend time right now learning it, it's not that important currently, it will be something for the future).

It's been a year since I started using KiCAD, and I now like it a lot, despite some things being clunky, a lot of things are great. I donated a bit of money to them today, since they are on a funding drive again.

RE: 100W USB Type-C Power Delivery Source: Getting Started

wolfgangfriedrich — Wed, 14 Dec 2022 14:27:57 GMT

Hello shabaz,

The updated layout looks great, good update. the outer layers are much more effective for heat dissipation than the internal ones. The caps and inductor without thermal relief will be very hard to solder without good pre-heating. I know as I am working with a 2oz board at the moment.

I think the NTC should be placed close to the hottest place on the board. As you said, could be done on the next revision or on wires to test is with this board.

Putting the heat sink on the bottom should work well, as the contact area is much bigger.

I am really looking forward to your results.

RE: 100W USB Type-C Power Delivery Source: Getting Started

wolfgangfriedrich — Wed, 14 Dec 2022 02:14:12 GMT

This is a really interesting project, and you are moving really fast on it.

Looking at the switcher, I am concerned about the thermal performance. Assuming best case at 100W, there is 5W of heat to be dissipated through convection at the nice metal housing when the heat gets off the board. The switcher datasheet gives all thermal parameters on a 8.5 mm^2 board with (!) 4 layers of 2 oz copper. This is massive and by the way really tough to solder. Even then they are claiming 32degC/W temp rise from ambient to junction. If you still can, add as much copper as possible on the Vin and SW side and more vias close to the pin. And there are small 3x3 mm^2 heat sinks with double sided sticky thermal transfer tape available, the design might benefit from that as well.

This will be a great little tool.

RE: 100W USB Type-C Power Delivery Source: Getting Started

shabaz — Tue, 13 Dec 2022 18:16:56 GMT

(Updated the blog post with easier-to-see PCB images).

RE: 100W USB Type-C Power Delivery Source: Getting Started

michaelkellett — Tue, 13 Dec 2022 15:52:22 GMT

Hello Shabaz, interesting project. I see that you only have one power outlet. If you want two or more do you need an additional interface and DC-DC chip for each one ?

I don't like the package the DC-DC converter is in, with those horrible semi- buried contacts.

How will you apply solder paste for them ?

RE: 100W USB Type-C Power Delivery Source: Getting Started

genebren — Tue, 13 Dec 2022 15:21:12 GMT

This looks like a great project and one that clearly addresses some of the power issues that might be coming your way. I look forward to seeing more about your design as you progress.