2 layers96.5 × 98 mm
Half bridge
profdc9/DRSSTC-PCB-Pack
A pack of PCBs for a dual resonant solid state tesla coil setup. Pretty much everything you need.
78 parts59
4 layers128 × 72.5 mm
Flyback Driver V1
Operationorange01/Flyback-Driver1driver for high voltage flyback transformer
- Size
- 128 × 72.5 mm
- Copper layers
- 4
- Thickness
- 1.6 mm
- Parts
- 120
- Nets
- 91
- Pads
- 399
- Tracks, vias
- 921, 176
- Pours
- 5
- Routed
- Yes
- KiCad
- KiCad 10.0 (file 20260206)
- Created
- 7 Aug 2026
- Updated
- 22 Oct 2026
Overview
Flyback Driver V1 is an open-source printed circuit board by Operationorange01, from the Operationorange01/Flyback-Driver repository on GitHub. It is a 4-layer board of 128 × 72.5 mm with 120 parts on 91 nets, routed with 921 tracks and 176 vias.
It is built around the LM2596S-ADJ, TPS62130RGT and UCC27511ADBV, with the 74HC132D, LM393 and IRLZ44N among its other parts. Its parts include 34 resistors, 33 capacitors, 11 ICs, 6 diodes and 4 connectors. It belongs with the STM32 boards of this library.
Main components
12
LM2596S-ADJ
TO-263-5-40℃~+125℃@(TA) 1 1.2V~37V 150kHz 3A 40V 80uA Adjustable Buck Buck Built-in No TO-263-5 DC-DC Converters ROHSUMWDC-DC Converters
TPS62130RGT
VQFN-16-EP(3x3)-40℃~+85℃@(TA) 1 17uA 2.5MHz 3A 3V~17V 900mV~6V Adjustable Buck Buck Built-in Yes QFN-16-EP(3x3) DC-DC Converters ROHSTexas InstrumentsDC-DC Converters
UCC27511ADBV
SOT-23-6-40℃~+140℃ 1 1V~1.2V 2.2V~2.4V 4.5V~18V 4A 7ns 8A 8ns IGBT、MOSFET Low Side Under Voltage Protection SOT-23-6 Gate Drivers ROHSTexas InstrumentsGate Drivers
74HC132D
SO-14-40℃~+125℃ 1.5V~4.2V 2 21ns@6V,50pF 2V~6V 2uA 3.7V~4.5V、5.2V~6V 300mV~1.2V 4 400mV 5.2mA 5.2mA 74HC Series NAND Gate Schmitt trigger SOIC-14 Logic Gates ROHSNexperiaSpecialty Logic
LM393
SOP-8-16V~16V 0℃~+70℃ 2 2.5mA 250nA 2V~36V 36V 5mV 5nA Fail-safe function Open-drain SOP-8 Comparators ROHSMSKSEMIComparators
IRLZ44N
TO-22055V 47A N-Channel HEXFET® Power MOSFETInfineon TechnologiesUncategorised
1N4742A
DO-41-65℃~+200℃ 1 Independent 11.4V~12.6V 12V 1W 5uA@9.1V 700Ω 9Ω DO-41 Zener Diodes ROHSonsemiZener Diodes
IRFP460
TO-247MOSFETsMinos
SMAJ12CA
DO-214AC(SMA)ESD And Surge Protection (TVS/ESD)hongjiacheng
SMCJ33A
SMC(DO-214AB)ESD And Surge Protection (TVS/ESD)hongjiachengSS36
SMA(DO-214AC)-55℃~+125℃ 3A 500uA@60V 60V 700mV@3A Independent SMA(DO-214AC) Schottky Diodes ROHSMDDSchottky Diodes
UF4007
DO-41-50℃~+150℃ 1.7V@1A 1A 1kV 30A 5uA@1kV 75ns DO-41 Fast Recovery / High Efficiency Diodes ROHSMDDFast Recovery / High Efficiency Diodes
README
README.mdFlyback Driver
This is a driver for a High Voltage Flyback Transformer.
We are planning on using it in the next stage in our research on EHD propulsion. You can read our preprint from last year here: https://doi.org/10.31224/6625
Features:
- Variable duty cycle
- Variable frequency
- Current/Voltage Sensing
- Current/Voltage Regulating 6V to 25V, digitally adjustable via 12-bit DAC about 5mV resolution
- Rotary encoder for control
- OLED Display
- Indicator Lights
- Soft Startup
- Hardware overcurrent protection, independent of firmware
- Latching fault shutdown
- Adjustable trip threshold
- RCD clamp with tunable clamp voltage
PCB
Made in KiCad. The full schematic is in assets/schematic.pdf.
Main parts:
- MCU: STM32F103C8T6
- Flyback switch: IRFP460 (500V, 20A) driven by a UCC27511A gate driver
- Supply regulation: LM5117 buck controller with two MCP4725 12-bit DACs for digital voltage/current setpoints
- Sensing: INA226 current/voltage monitor
- Protection: LM393 comparator + 74HC132 latch for hardware overcurrent shutdown
- Logic rails: LM2596 and TPS62130 bucks
Custom footprints are in pcb/libraries.
Firmware
made some basic firmware but is still untested
disclaimer, most of the firmware was made using the help of ai because I don't know enough c
BOM
The full BOM with reference designators, Digi-Key part numbers and datasheets is in BOM.csv. Parts on Digi-Key come to about $94.
Not on the Digi-Key order yet:
- 1x 0.91" 128x32 I2C OLED (U4)
- 1x 2x4 2.54mm pin header (J1)
- 1x 1x5 2.54mm pin header (J2)
- 16x test points (TP1–TP16)
Parts
120| Qty | Value | Footprint | References |
|---|---|---|---|
| 16 | TestPoint | TestPoint:TestPoint_THTPad_D1.5mm_Drill0.7mm | TP1, TP2, TP3, TP4, TP5, TP6, TP7, TP8, TP9, TP10, TP11, TP12, TP13, TP14, TP15, TP16 |
| 11 | 100nF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C1, C2, C3, C4, C7, C18, C20, C22, C23, C25, C29 |
| 11 | 10K Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R4, R5, R9, R13, R18, R22, R24, R25, R26, R28, R30 |
| 4 | 10uF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C5, C17, C19, C31 |
| 3 | 10 Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R1, R15, R16 |
| 3 | 1uF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C8, C12, C13 |
| 3 | 330 Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R6, R7, R8 |
| 3 | LED | LED_SMD:LED_0805_2012Metric_Pad1.15x1.40mm_HandSolder | CRT_LMT, FAULT, STATUS |
| 2 | 100K Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R11, R14 |
| 2 | 10uF | Capacitor_SMD:C_1210_3225Metric_Pad1.33x2.70mm_HandSolder | C24, C26 |
| 2 | 1K Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R21, R32 |
| 2 | 1nF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C11, C28 |
| 2 | 4.7k | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | I2C_SCL_PULLUP1, I2C_SDA_PULLUP1 |
| 2 | IRLZ44N | Package_TO_SOT_THT:TO-220-3_Vertical | Q_HS1, Q_LS1 |
| 2 | MCP4725xxx-xCH | Package_TO_SOT_SMD:SOT-23-6 | U3, U10 |
| 2 | Screw_Terminal_01x02 | TerminalBlock_Phoenix:TerminalBlock_Phoenix_MKDS-3-2-5.08_1x02_P5.08mm_Horizontal | J3, J4 |
| 1 | 0.033 Ohm 1 W | Resistor_SMD:R_2512_6332Metric_Pad1.40x3.35mm_HandSolder | CUR_SEN_R1 |
| 1 | 0.1uF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C6 |
| 1 | 0.47uF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C33 |
| 1 | 100 Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R29 |
| 1 | 1000uF | Capacitor_THT:CP_Radial_D12.5mm_P5.00mm | C14 |
| 1 | 100k Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R34 |
| 1 | 100kΩ, 2W | Resistor_THT:R_Axial_DIN0617_L17.0mm_D6.0mm_P25.40mm_Horizontal | R23 |
| 1 | 100uF 50V | Capacitor_THT:CP_Radial_D8.0mm_P3.50mm | C15 |
| 1 | 10k | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | ENC_SW_PULLUP1 |
| 1 | 10k Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R3 |
| 1 | 10nF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C27 |
| 1 | 130K Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R17 |
| 1 | 13K Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R10 |
| 1 | 150uH >1.5A | wurth:INDM125125X800N | L2 |
| 1 | 15m Ohm | Resistor_SMD:R_2512_6332Metric_Pad1.40x3.35mm_HandSolder | R19 |
| 1 | 15uH 8A | wurth:L_Wurth_WE-XHMA-1090 | L1 |
| 1 | 17.4K Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R27 |
| 1 | 1N4148 | Diode_THT:D_DO-35_SOD27_P7.62mm_Horizontal | D3 |
| 1 | 1N4742A | Diode_THT:D_DO-41_SOD81_P10.16mm_Horizontal | D6 |
| 1 | 2.2nF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C10 |
| 1 | 2.2uH | wurth:L_Taiyo-Yuden_LCXND4040 | L3 |
| 1 | 220nF | Capacitor_THT:C_Rect_L18.0mm_W5.0mm_P15.00mm_FKS3_FKP3 | C21 |
| 1 | 220uF 25V LOW ESR | Capacitor_THT:CP_Radial_D8.0mm_P3.50mm | C16 |
| 1 | 22nF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C9 |
| 1 | 22pF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C30 |
| 1 | 22uF | Capacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C32 |
| 1 | 300k Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R33 |
| 1 | 33K Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R31 |
| 1 | 4.07K Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R12 |
| 1 | 4.7 Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R2 |
| 1 | 7.32K Ohm | Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolder | R20 |
| 1 | 74HC132 | Package_SO:SOIC-14_3.9x8.7mm_P1.27mm | U11 |
| 1 | Conn_01x05_Pin | Connector_PinHeader_2.54mm:PinHeader_1x05_P2.54mm_Vertical | J2 |
| 1 | Conn_02x04_Top_Bottom | Connector_PinHeader_2.54mm:PinHeader_2x04_P2.54mm_Vertical | J1 |
| 1 | ER_OLEDM0.91_1x-I2C | Display:ER_OLEDM0.91_1x-I2C | U4 |
| 1 | INA226 | Package_SO:TSSOP-10_3x3mm_P0.5mm | U5 |
| 1 | IRFP460 | Package_TO_SOT_THT:TO-247-3_Vertical | Q1 |
| 1 | LM2596S-ADJ | Package_TO_SOT_SMD:TO-263-5_TabPin3 | U7 |
| 1 | LM393 | Package_SO:SOIC-8_3.9x4.9mm_P1.27mm | U9 |
| 1 | LM5117PSQ/NOPB | Package_DFN_QFN:WQFN-24-1EP_4x4mm_P0.5mm_EP2.6x2.6mm_ThermalVias | U6 |
| 1 | NetTie_2 | NetTie:NetTie-2_SMD_Pad0.5mm | NT1 |
| 1 | PMOS | Package_TO_SOT_THT:TO-220-3_Vertical | Q2 |
| 1 | RotaryEncoder_Switch | Rotary_Encoder:RotaryEncoder_Alps_EC11E-Switch_Vertical_H20mm_MountingHoles | SW1 |
| 1 | SMAJ12CA | Diode_SMD:D_SMA | D1 |
| 1 | SMCJ33A | Diode_SMD:D_SMC | D2 |
| 1 | SS36 | Diode_SMD:D_SMC | D4 |
| 1 | STM32F103C8Tx | Package_QFP:LQFP-48_7x7mm_P0.5mm | U1 |
| 1 | TPS62130 | Package_DFN_QFN:VQFN-16-1EP_3x3mm_P0.5mm_EP1.68x1.68mm_ThermalVias | U8 |
| 1 | UCC27511ADBV | Package_TO_SOT_SMD:SOT-23-6 | U2 |
| 1 | UF4007 | Diode_THT:D_DO-41_SOD81_P10.16mm_Horizontal | D5 |
Questions
How big is the Flyback Driver V1 PCB?
It measures 128 × 72.5 mm and has 4 copper layers, 1.6 mm thick.
What parts does the Flyback Driver V1 use?
120 parts, built around the LM2596S-ADJ, TPS62130RGT, UCC27511ADBV and 74HC132D. 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 Flyback Driver V1 KiCad files?
From the Operationorange01/Flyback-Driver repository on GitHub, at the commit this page was made from: the board is pcb/Flyback Driver V1.kicad_pcb and its schematic pcb/Flyback Driver V1.kicad_sch. PCBKit opens the board in the browser, with nothing to install.
Can I use the Flyback Driver V1 design in my own project?
Its repository states no licence, so its author keeps all rights: ask Operationorange01 before reusing the design.
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