Case for 4 Channels LM2596 DC to DC Buck Converter

LM2596 Case Design

Model Description: Custom Enclosure for 4 Channels LM2596 DC-to-DC Buck Converter

Overview:

This document outlines the design of a custom enclosure for the 4 Channels LM2596 DC-to-DC Buck Converter (Amazon.com | 4 Channels LM2596 DC to DC Buck Converter), supporting input voltages of 13-35V and providing simultaneous output voltages of 3.3V, 5V, 12V, and adjustable voltage. The enclosure is tailored to ensure ease of use, proper cooling, and compatibility with common ESP32 board power requirements.

Design Motivation:

As I frequently require a versatile power supply for projects involving ESP32 boards and similar devices, I sought to create a modular and reliable power supply unit capable of delivering multiple regulated outputs. This design is my first more complex project using Fusion360.

Key Features of the Enclosure:

Input Compatibility:

Supports a 24V DC input using a standard power adapter: Netzteil 24V 3A AC/DC Netzadapter SVNONVE | Amazon

Output Power Supply:

Amazon.com | 4 Channels LM2596 DC to DC Buck Converter

Provides simultaneous outputs of:

3.3V (max. 3A, 9.9W)

5V (max. 3A, 15W)

12V (max. 3A, 36W)

Adjustable voltage (max. 3A, up to 36W depending on the set voltage)

Important Limitation: The total current for all channels must not exceed 5A to avoid overloading the module.

Cooling Management:

Cooling Considerations: The LM2596 module requires effective cooling to sustain its maximum output. The enclosure is designed to accommodate heat sinks and optional ventilation holes or active cooling elements (e.g., fans).

Heat Sinks Used: I repurposed Raspberry Pi heat sinks from my stock: 32 Stück (8er Set) Kühlkörper für Raspberry Pi 4B | Amazon

Ease of Assembly:

The enclosure includes mounting holes for securing the LM2596 module.

Proper spacing for input and output wiring, along with ports for cables.

Use Cases:

Ideal for powering ESP32 boards and other low-power IoT devices.

Supports multiple simultaneous projects with different voltage requirements.

Additional Notes:

Previous Experience: This design builds upon my prior work, including an enclosure for a 4-channel relay used with OctoPrint in a 3D printing housing. Just check my designs.

Design Software: Fusion360 was used to create the CAD model.

Suggestions for Use: Equip the LM2596 module with heat sinks and, if necessary, add active cooling to maintain performance under high loads.

Have Fun!

This project combines functionality and customization, offering a versatile solution for powering multiple devices in your workspace. Let me know if you need further details or design files!

Update 01/2025:

Availability Notice: The LM2596 board used in this design seems to be not widely available anymore, and as such, this design is considered end of life  and won't be maintained.

However, potential successors to this board may feature different switch types or layouts, making them incompatible with this enclosure design without modifications.

Potential reference: Amazon reference B0BSLKTWXF but the switch is different.

Future users should explore alternative power supply modules for similar applications.