Mini PSU with Optional IR Feature

thingiverse

This is a case for a very small DC power supply circuit board that is inexpensive and available in a variety of voltages. There is an option to include a common IR sensor that will power the PSU for a selectable time. The IR version includes an optional cavity to encapsulate a "classic" US appliance plug. Most versions have the option to add pegboard mounting tabs. <h5>Background</h5> I needed some short lengths of light strip style lighting, and I was unimpressed with the appearances and performance of the thousands of inexpensive light strip products on Amazon (e.g.). I need lots of lumens, and the nice looking battery units don't deliver. Given that I cannot easily hide the power source, the looks of the power supply and cables are a factor. I have plenty of good quality scraps of LED strips, so I came up with this solution. The IR sensor works on the line AC input, with the output wired to the PSU input. The PSU is only powered when the sensor is triggered. In all versions, you will need to print a bottom, and a lid. If you use the plug encapsulation (US type), print the appropriate bottom AND also print the small end piece that covers half of the plug. The compatible pegboard clip is a remix that I did of https://www.thingiverse.com/thing:2108670. <h5>Other parts/tools:</h5> 1. Power supply. I have used the 12V and the 24V versions. https://www.amazon.com/dp/B08545K26C 2. IR sensor. https://www.amazon.com/dp/B0771HGTRQ 3. Plug cut from an old appliance 4. Lid screws (3). These are the rolling thread types which are designed to work with plastic. 3/8" long with a #3-24 thread. https://www.amazon.com/gp/product/B00GDYDCC0 5. Super glue (gel type), and (optional) "activator" 6. Solder, wire scraps, and (suggested) heat shrink tubing 7. To power your load: two-conductor "security cable", 22 gauge. https://www.amazon.com/gp/product/B077MHW8QH <h5>Printing Tips</h5> I use PETG and I highly recommend it over PLA for functional parts that need to fit together. PLA tends to shrink over time, but not uniformly. If you'd like the lid to have ventilation: print it without top/bottom layers, set your infill pattern to grid or honeycomb, and set your walls to be 3 layers thick. The plug encapsulation end-piece prints with a small surface area on the print bed, so apply a glue stick on the print bed to prevent the piece from falling over during the print.