PowerBox – Power Supply Case for Zigbee Sensors

This project was designed to power Zigbee sensors such as the Xiaomi Mijia LYWSD03MMC or the Tuya TH05 or TH03, providing a longer-lasting and more affordable alternative to the traditional CR2032 coin cell battery.

Three different case versions are available:

🔋 AA Battery Version

• Uses two standard AA batteries in a typical battery holder.
• Theoretical battery life: 10 to 12 times longer than a CR2032 coin cell.
• More economical over time, thanks to the low cost and wide availability of AA batteries.

🧰 Required components:

• PLA 21,5g
• 1 AA battery holder (2×AA)
• 2 AA batteries
• Wires for soldering

🔋 AAA Battery Version

• Uses two standard AAA batteries in a typical battery holder.
• Theoretical battery life: 6 to 8 times longer than a CR2032 coin cell.
• Ideal when a smaller size is preferred while still extending battery life significantly..

🧰 Required components:

• PLA 18,9g
• 1 AAA battery holder (2×AAA)
• 2 AAA batteries
• Wires for soldering

🔋 Lithium Battery 102050 Version

• Powered by a rechargeable 1000 mAh lithium battery (model 102050).
• Includes a TP4056 charging module with micro-USB input and protection circuit.
• Theoretical battery life: 20 to 25 times longer than a CR2032 coin cell.

🧰 Required components: 

• PLA 12,3gr
• 1 lithium battery 102050 (3.7V, 1000 mAh)
• 1 TP4056 module (with micro-USB input and protection)

• Wires for soldering

  

📦 Printed components:

• Power supply case (version for batteries or lithium pack)
• Sensor mounting cover:
  • Compatible with Xiaomi and Tuya sensors.
  • Includes a tab to press the pairing button without opening the sensor.
  • Features two 5 mm holes, used for:
    • Aligning the cover when gluing it to the power case.
    • Routing the wires to be soldered to the sensor.
• Main case lid, which gives access to the battery or lithium pack.

⚙️ Mounting and Fixation:

• Both the sensor cover and the main lid are snap-fit, eliminating the need for screws.
  This makes assembly and disassembly easier and tool-free.
• The sensor cover should preferably be glued (e.g., with super glue) to the power case, forming a single block.
• The entire module (sensor + power case) is mounted on a surface using double-sided tape applied to the lid,
  allowing the case to be removed easily while the cover remains glued to the wall or object.

📐 Approximate dimensions:

• AA battery version: 65 × 43 × 20 mm
• AAA battery version: 58 × 43 × 17 mm
• Lithium battery version: 54 × 43 × 18.5 mm

🎯 Project goal:
To significantly increase the autonomy of Zigbee sensors, reduce battery replacement costs, and make maintenance easier—without compromising the sensors’ design or functionality.

🧵 Recommended material: PLA or PETG