MicroWatt PDU - 1U 10 inch rack Power Distribution

Warning: mains wiring requires following local legislation and having the appropriate skills or qualifications

Short summary

A printable 1U power distribution unit for a 10-inch mini rack, combining four USB-C PD ports that can deliver up to 65W each (5,9,12,20V) to power 1L PC's etc, four 12V DC outlets for routers/switches etc and a mains pass-through in one place.

Remixes may be needed for different power supplies, mounting spacing below, show me the units you have and I can make a version for you.
D361-200-24 177 × 50 × 23 mm mount hole spacing: 169 × 34 mm
D361-150-12 138 × 50 × 23 mm mount hole spacing: 130 × 34 mm

** If you enjoy this model, please consider buying me a coffee :)

Description

Small rack, lots of power bricks? MicroWatt PDU is my take on a 10-inch rack PDU: one 1U module to bring 4xUSB-C Power Delivery, 4x12V DC 5.5mm and a mains pass-through together for a mini homelab.

 The mini-rack community has already built plenty of useful PDUs, from compact IEC outlet panels to shared DC supplies and USB-C power systems. MicroWatt PDU follows that same aim of reducing the pile of adapters behind the rack, with a mix of outputs for equipment that uses different power connections.

 I use mine to power a Wi-Fi router, a 10 Gb switch, a PoE switch, a Dell Micro PC and an HP Mini PC, all housed in a LabRax rack.

 The finished unit combines:

• Two inexpensive LED power supplies: a 24V 200W unit for the USB-C board and a 12V 150W unit for the barrel outlets. These are readily available supplies rather than specialised rack hardware. Substitute suitable units you can source locally, matching the required output voltage and power; adjust the mounting points if their size or hole pattern differs.

• Four USB-C Power Delivery outputs: the CKCS board turns the 24V supply into negotiated USB-C power, with advertised output up to 65W per port and 5, 9, 12, 15 and 20V modes depending on the board variant. Most importantly all four outputs are completely independant! They will not drop devices when devices are added/removed! Use the outputs for 1-litre mini PC connected directly if they accept USB-C PD, or through a suitable PD trigger cable and PC power adapter. USB-C-to-barrel trigger leads also let these ports power compatible 5, 9 or 12V equipment.

• Four dedicated 12 V barrel outlets: useful for routers, small switches, modems, access points and other accessories that would otherwise each need a 12V power brick. Connect them with DC barrel male-to-male leads: 5.5 × 2.5 mm at MicroWatt PDU, with the equipment end sized to suit, commonly 5.5 × 2.1 or 5.5 × 2.5 mm.

• A switched, fused IEC inlet: accepts a standard IEC C13 power lead with your country's wall plug, so the same inlet can be used with locally available cables. The inlet's replaceable fuse provides mains overcurrent protection, and its switch controls the incoming power.

• An outgoing mains lead: powers equipment such as a PoE switch alongside the USB-C and 12 V devices, bringing the rack's different power connections together in one module.

All connections are at the rear, keeping the front of the rack tidy. The two supplies sit inside the chassis, reducing the collection of separate adapters behind the rack.

 There is plenty of airflow across the front, top and low-voltage side. The mains side remains solid and includes built-in cable-tie points to keep the wiring organised. A small two-colour MicroWatt PDU badge clips directly into the front hexagons and is included as an optional AMS file.

If you build one, post a Make and share what it powers. Different mini racks have different needs, so feedback, component alternatives and remixes are welcome. 

Printing

• ABS or PETG can be used, I have designed this to need no supports! Tested with ABS on a Bambu Lab X1C using a BIQU CryoGrip plate.

• The files are already oriented with the print faces down: the body prints faceplate-down, the lid exterior-face-down and the rear panel inner-face-down.

• Print the small test-fit coupons first to check the IEC inlet, DC sockets and heat-set inserts against your actual hardware before committing to the main body.

• The main body needs good bed adhesion, particularly under the faceplate wings. As the tall side walls print and shrink, they can pull the wings upwards from the plate. Use a clean, suitable build surface and add a brim if your material or plate needs it.

Hardware in the finished unit (There is a BOM in the assembly guide)

• D361-200-24, 24V 200W supply

• D361-150-12, 12V 150W supply

• CKCS four-port 65W USB-C charging board

• Four 9 × 9 x 12mm heatsinks, one on the inductor near each CKCS USB-C output

• PP4003 switched and fused IEC inlet

• Four DC-022B 2.5 mm panel sockets

• Three inline fuse holders 20mm, 10A fuses

• M3 heat-set inserts, 4.5 mm maximum OD × 3 mm long

Features

• Rounded 1U faceplate corners and three horizontal rack slots on each side

• Hexagonal front and top ventilation

• Additional right-wall and right-floor ventilation

• Solid left/mains side with two built-in cable-tie bridges

• Removable rear connector panel held securely around its edges and near the centre

• Heat-set insert mounting for both PSUs and the lid

• Dedicated mounting points for the CKCS board

• Rear-panel channel designed to print cleanly without a separate support piece

• Optional two-colour clip-in MicroWatt PDU badge

• Editable OpenSCAD source included for anyone who wants to remix the layout