ULTIMATE DPS5005 Case (up to 190W) and built in separate 5V PSU (10W)

Overview:

A 48V AC to DC power supply supplies the DPS5005 module with power. The module outputs via the two binding posts below it. An additional 5V power supply outputs 5V via two USB A connectors (this PSU is housed inside a small 3D printed enclosure inside the main enclosure).

Both supplies can be turned on and off independently of each other.

Two fans on the side cool the electronics. A DC-DC buck converter converts the 48V to 12V or lower for the fans. You might want to add a switch to turn the fans off if not needed.

I have supplied the Fusion360 project files, edits and tweaks are easily made!

Size: 122.50 mm x 135.00 mm x 83.00 mm (depth (length), width, height)

Build it completely at your own risk! I take no responsibility whatsoever for any damages. Only work with mains electricity if you have the necessary qualifications!

Here are the components used (I provided links to exemplary offers):

- DPS5005 (similar models will fit as well) https://www.aliexpress.com/item/4000927433800.html - 48V 4A PSU module (use other voltage variant depending on DPS module) https://www.aliexpress.com/item/1005003515212831.html - 5V 2A PSU module https://www.joom.com/de/products/5e12eee88b45130101f622a0 Note: this variant doesn't seem to be available anymore. Similar modules are still sold. Adapt the design if necessary. - KCD4 power switch https://www.aliexpress.com/item/32831918654.html - KCD1-104 power switch https://www.aliexpress.com/item/4000042259104.html - Red and black binding post https://lcsc.com/product-detail/Banana-Connectors-Alligator-Clips-Test-Rings_Changzhou-Amass-Elec-24-302-2_C106271.html https://lcsc.com/product-detail/Banana-Connectors-Alligator-Clips-Test-Rings_Changzhou-Amass-Elec-24-302-1_C99100.html - 2x 40x40x10mm Fans - XL7015E1 buck converter module (optional for fans) https://www.aliexpress.com/item/1005003492207083.html - IEC power socket https://www.aliexpress.com/item/32804170262.html - M3 screws (~12mm and ~4-6mm) and washers - M3 threaded inserts https://www.aliexpress.com/item/4000909684199.html - 2x USB A female connectors https://www.aliexpress.com/item/32918366266.html - Wires & crimp connectors etc. - 4x rubber feet All links provided are for reference only and to help you find the correct part.

Use the renders to see how to assemble the case. Print with the front side facing the build plate. No supports should be necessary.

Just a word of caution, the space inside the PSU is quite crammed, you need a bit of patience to assemble it. :)

I made two renders of the case: