2 layers300 × 400 mm
Sao connector board
flummer/sao-wall
Design for a SAO display PCB, power and control board
42 parts2CC-BY-SA-4.0
2 layers120 × 100 mm
Usb pd pico controller
flummer/sao-wall2Design for a SAO display PCB, power and control board
- Size
- 120 × 100 mm
- Copper layers
- 2
- Thickness
- 1.6 mm
- Parts
- 64
- Nets
- 76
- Pads
- 267
- Tracks, vias
- 509, 238
- Pours
- 1
- Routed
- Yes
- KiCad
- KiCad 10.0 (file 20260206)
- Created
- 27 Apr 2026
- Updated
- 3 Aug 2026
Overview
Usb pd pico controller is an open-source printed circuit board by flummer, from the flummer/sao-wall repository on GitHub, published under the CC-BY-SA-4.0 licence. It is a 2-layer board of 120 × 100 mm with 64 parts on 76 nets, routed with 509 tracks and 238 vias.
It is built around the AP63203WU, ESDA25P35-1U1M and ESDA25W, with the MBR120VLSFT1G-TP, STL6P3LLH6 and TS5220A among its other parts. Its parts include 24 capacitors, 9 resistors, 7 connectors, 5 ICs and 4 diodes. It belongs with the power and lEDs and displays boards and the RP2040 boards of this library.
Main components
6
AP63203WU
TSOT-23-6-40℃~+85℃@(TA) 1 1.1MHz 22uA 2A 3.3V 3.8V~32V Buck Built-in Fixed Overcurrent Protection、Light load efficient mode、Cycle-by-cycle current limiting、Hiccup current limiting、EMI optimization (spread spectrum) Step-down type Yes TSOT-23-6 DC-DC Converters ROHSDiodes IncorporatedDC-DC Converters
ESDA25P35-1U1M
DFN1610-2-55℃~+150℃ 1 1.4kW@8/20us 200nA 22V 24.6V 35A@8/20us 41V IEC 61000-4-2 TVS Unidirectional DFN1610-2 ESD and Surge Protection (TVS/ESD) ROHSSTMicroelectronicsESD And Surge Protection (TVS/ESD)
ESDA25W
SOT-323-3L-40℃~+125℃ 15A 1uA 2 24V 25V 25V 400W 65pF ESD IEC 61000-4-2 Unidirectional SOT-323-3L ESD and Surge Protection (TVS/ESD) ROHSSTMicroelectronicsESD And Surge Protection (TVS/ESD)
MBR120VLSFT1G-TP
SOD-123FUncategorisedTECH PUBLIC
STL6P3LLH6
PowerFLAT-8(3.3x3.3)1 P-Channel 1.45nF 120pF 12nC@24V 1V 2.9W 30V 30mΩ@10V 6A PowerFLAT-8(3.3x3.3) MOSFETs ROHSSTMicroelectronicsMOSFETs
TS5220A
SMD-4P,5.2x5.2mm-20℃~+80℃ 100 thousand cycles 12V 2.5N 2mm 5.15mm 5.15mm 50mA Gold Gull Wing No Round Button SPST Surface Mount,Vertical Without Bracket SMD-4P,5.2x5.2mm Tactile Switches ROHSSHOU HANTactile Switches
README
README.mdSAO Wall
This is a design for a large PCB (300x400mm) with 16 SAO connectors to work either as a standalone display (fits in an IKEA RÖDALM picture frame) or be monted along with other panels to form a larger wall for displaying many SAOs.
This is heavily inspired by Brian Benchoffs SAO Wall, that has been used at several Supercon events, but this design does a few things slightly different, not least the power setup.
Main concept and idea
The design is separated into two parts:
- SAO Connector board, which is the large PCB, that has all the connectors, polyfuses for each output and then a set of connectors for hooking up to the 4 power rails, the 2 I2C busses and all the GPIO pins for all SAOs
- USB-C PD and Pico controll board is the smaller board that has the voltage regulators (4x AP63203WU-7 buck converters), USB-C PD controller (STUSB4531) and a footprint for a Raspberry Pi Pico (1 or 2).
The setup with two boards is done so that the more generic part (the connector PCB) that is also a bit on the expensive side can be ordered once and maybe a combined order for multiple people, and then the more opinionated element with the powering circuit and maybe a micro controller can be easier made in low volume (most simple is a piece of proto board and a simple 3.3v poser supply).
The USB-C PD power setup that is included here is meant to work nicely with most USB-C power supplies and at the same time be able to power all 16 SAOs to the full specification of the SAO standard (250mA @ 3.3V for each SAO).
The Raspberry Pi Pico is connected very similar to hos the Hackaday SAO Badge was made, with 2 I2C busses (using the same pins) and hooked up to GPIO pins of most of the SAOs (10 out of the 16) as there is a limited number of available connections on the Pico. It's not 100% pin compatible with the Hackaday SAO Badge, but it should be an easy tweak if you would like to run the same firmware.
Designed in KiCad v10
To open the project, you will need to install the most recent release (v10), KiCad v9 or earlier won't open this design directly.
Electronics schematics for the connector board as a PDF file and Electronics schematics for the USB-C PD and Pico control board as a PDF file are included for reference.
License
The hardware design of the main branch of this repository is released under the following license:
- the "Creative Commons Attribution-ShareAlike 4.0 International License" (CC BY-SA 4.0) full text of this license is included in the LICENSE file and a copy can also be found at http://creativecommons.org/licenses/by-sa/4.0/
Parts
64| Qty | Value | Footprint | References |
|---|---|---|---|
| 9 | 100nF, X5R/X7R, 50V | Capacitor_SMD:C_0603_1608Metric | C4, C6, C7, C11, C12, C16, C17, C21, C22 |
| 8 | 22uF, X5R/X7R, 25V | Capacitor_SMD:C_1206_3216Metric | C8, C9, C13, C14, C18, C19, C23, C24 |
| 4 | 10K | Resistor_SMD:R_0603_1608Metric | R1, R2, R3, R4 |
| 4 | 10uF, X5R/X7R, 35V | Capacitor_SMD:C_1206_3216Metric | C5, C10, C15, C20 |
| 4 | 6.8uH | Inductor_SMD:L_Sunlord_MWSA1005S | L1, L2, L3, L4 |
| 4 | AP63203WU | Package_TO_SOT_SMD:TSOT-23-6 | U2, U3, U4, U5 |
| 4 | LOGO | LOGO | G***, G***, G***, G*** |
| 4 | TestPoint | TestPoint:TestPoint_Pad_D1.0mm | TP1, TP2, TP3, TP4 |
| 2 | 1K | Resistor_SMD:R_0603_1608Metric | R5, R9 |
| 2 | 1uF | Capacitor_SMD:C_0603_1608Metric | C2, C3 |
| 2 | Conn_01x20_Socket | Connector_PinSocket_2.54mm:PinSocket_1x20_P2.54mm_Vertical | J6, J7 |
| 2 | Conn_01x26_Socket | Connector_PinSocket_2.54mm:PinSocket_1x26_P2.54mm_Vertical | J3, J4 |
| 2 | ESDA25P35-1U1M | Diode_SMD:ST_QFN-2L_1.6x1.0mm | D2, D4 |
| 2 | LCSC C145956 | Connector_JST:JST_SH_SM04B-SRSS-TB_1x04-1MP_P1.00mm_Horizontal | J1, J2 |
| 1 | 100 | Resistor_SMD:R_0603_1608Metric | R8 |
| 1 | 100K | Resistor_SMD:R_0603_1608Metric | R6 |
| 1 | 22K | Resistor_SMD:R_0603_1608Metric | R7 |
| 1 | 4.7uF, 35V | Capacitor_SMD:C_0805_2012Metric | C1 |
| 1 | ESDA25W | Package_TO_SOT_SMD:SOT-323_SC-70 | D3 |
| 1 | LOGO | Aesthetics:HXR_logo_small | G*** |
| 1 | MBR120VLSFT1G | Diode_SMD:D_SOD-123 | D1 |
| 1 | STL6P3LLH6 | SMD_Semiconductors:TRANS_STL6P3LLH6 | Q1 |
| 1 | STUSB4531QTR | Package_DFN_QFN:QFN-16-1EP_3x3mm_P0.5mm_EP1.7x1.7mm | U1 |
| 1 | TS5220A | Button_Switch_SMD:SW_SPST_TL3342 | SW1 |
| 1 | USB_C_Receptacle_USB2.0_16P | Connector_USB:USB_C_Receptacle_XKB_U262-16XN-4BVC11 | J5 |
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Questions
How big is the Usb pd pico controller PCB?
It measures 120 × 100 mm and has 2 copper layers, 1.6 mm thick.
What parts does the Usb pd pico controller use?
64 parts, built around the AP63203WU, ESDA25P35-1U1M, ESDA25W and MBR120VLSFT1G-TP. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.
Where can I download the Usb pd pico controller KiCad files?
From the flummer/sao-wall repository on GitHub, at the commit this page was made from: the board is usb_pd_pico_controller/usb_pd_pico_controller.kicad_pcb and its schematic sao_connector_board/sao_connector_board.kicad_sch. PCBKit opens the board in the browser, with nothing to install.
Can I use the Usb pd pico controller design in my own project?
Its repository publishes it under the CC-BY-SA-4.0 licence: you may reuse it on that licence's terms (keep the author's notice, and for a copyleft licence share your changes alike).