XT60 to USB quick charger housing

Use case

If you need a USB quick charging capability at some place where you have any DC voltage between 6V and 32V available, the solution is very cheaply available online (around 2 to 3 € or $ per piece). My personal application was to have USB charging within my motorbikes tank bag.

These little PCBs are sold on Ebay, Amazon (at least here in Germany) and other online shops. I got mine in a set of 5 for just over 10€. https://www.amazon.de/dp/B08M3MPKF9

I figured that a XT60 connection, as commonly used in RC model flying, would allow for a quick disconnection of the feeding wire. So I designed this snap housing that has a fitting cutout for the USB A connector on the PCB on one side, and a fitting cutout for XT60 on the other side. 

You need to glue in the PCB and the XT60 connector. I figured that hot glue is the perfect choice for almost all applications, as it is fast and strong. I have tested if the PCB would warm up enough to soften the hot glue, but it came never close to that. Only if you run your electronics in very hot environments, like my black tank back in the bright summer sun, you may choose to go for epoxy glue, which does not care for temperature.

If you have a XT60 connector with a little protrusion like I had, that is ideal as it holds the connector very strongly after it is glued in.

Printing

Very simple, just print the parts in the uploaded orientation with 100% infill and 3 perimeters. It is a very quick print anyway. I have tested the design both from PLA and PETG, both worked fine.

Assembly

As said above, I recommend hot glue. Put a bit of it on the bottom side of the PCB first and glue it into the bottom housing. Then put a bit of hot glue in the groove for the XT60 connector and press it in. Then put hot glue into the groove of the top part and on the USB A connector and press the top housing on. After a few seconds of cooling, your charger is ready to be used.