Wireless Qi Phone Charging Pad

Instructions

Purchase the charger internals from the eBay link above. There are several similarly shaped charger pcb's so this is the only way to guarantee fit. Plan ahead as it can take 2-3 weeks for these to arrive from China. Prepare your enclosure materials. I recommend using .20" (5mm) thick for both top and bottom. You will be cutting 3mm deep in order to fit the internals and you want to leave enough material thickness above the coil for strength, but not so much that it will interfere with the ability to charge wirelessly. If you will be engraving directly over the coil you should plan accordingly so that you do not damage the coil or excessively weaken the enclosure. I used wood that I had prepared by book matching, to give the allusion of a solid block of wood when assembled. The svg is prepared with both top and bottom parts in one file. You only need to cut each part once. They are oriented so that if you center the file over the book match centerline the grain structure of the finished parts will meet. When cutting, begin by cutting the internal features first. The cut depths are listed on the file in millimeters. Before moving on to cut out the internals test fit the coil and pcb in their respective pockets to ensure your cut depth is enough to sink the internals flush or better. I had a few solder bumps that needed grinding. This is much easier to correct before the parts are cut free. When cutting the parts free I find it easiest to leave a few small tabs of material on the final pass uncut by retracting the bit, advancing Origin slightly and then continuing with the cut. These tabs are easily cut free and sanded off. To assemble the chargers I used quick setting super glue to glue the coil into it's recess first. I could then tuck any excess wiring into the pocket and position the pcb for final assembly. For added insurance put a layer of tape between the pcb and the coil base. To join the halves I used a bead of thicker, slower setting super glue around the perimeter. Any squeeze out is easily sanded off when sanding the tabs. (Optional) If you want to add a custom touch you can engrave the top surface. Place the svg for the top (coil side) on a piece of scrap and change the perimeter path to pocket. Your pocket should be at least as deep as the assembled charger. Add some reliefs to the edges of the pocket for your fingers to make removing the charger from the pocket easier. Use negative offsets to get a snug fit. By using the svg for the top you can easily see where the wood is thick enough to engrave, but be careful because the internal pocket is actually the reverse image since the part has been flipped over. The micro USB connector should face opposite the wire recess. Finish as desired.