How to Make a Mobile Power Bank 2026

How to Make a Mobile Power Bank, we will teach you how to make a mobile power bank, which will be very helpful when traveling. In these instructions, I will show you how you can create your own power bank using readily available and inexpensive components. This backup battery contains a 18650 li-ion battery from an old laptop or you can buy a new one. Later, I made a wooden casing with cool-looking plexiglass lights for a cooler aesthetic feel. I'll walk you through each of the steps to build this.

Watch the video on how to make a mobile power bank:

Video Link.

The specifications are:

• Capacity: 6600mAh (Expandable)
• Output voltage: 5V

Step 1: Required Materials

• 18650 li-ion battery
• TP 4056 battery protection module
• 6009 Boost Converter Module
• LED
• 330 ohm resistance
• USB female connector
• Welding kit
• Switch
• Plywood (3/4″ and 1/4″ thick)

Some basic carpentry tools such as drill, hacksaw, chisel, etc.

Step 2: Make the battery

• The terminals of the 18650 batteries are cleaned using an IPA solution.
• Apply a little flux and use the soldering iron to blow up the surface of the battery terminal.
• Also strip the wire insulation at the ends and tin them. Batteries must be connected in parallel configuration. Solder the wires to the battery and do not overheat the battery during soldering.
• My batteries were original Samsung ICR18650-22 model and I suggest you use good quality batteries for longer life and safety.
• I am using 3 batteries in parallel to obtain a total capacity of 6600 mAh. You may want to add more batteries in parallel to increase capacity.
• Then tie down the batteries using electrical tape or kapton tape.

Note:It is important to charge the batteries to the same voltage level before connecting them in parallel. Otherwise, the battery with higher potential will be discharged to a lower potential and a large current will flow through them, resulting in excessive heat.

Step 3: Battery Protection Circuit

• The terminals of the TP4056 battery protection module are indicated by symbols.
• The battery must be connected to terminals B+ and B-.
• The output is connected to the Output + and Output - terminals. Any mobile phone charger with USB can be used to charge the battery.
• The TP4056 module protects the battery against overcharging and short circuits. Lithium batteries should be handled with care. The voltage level should be in the range of 2.7V to 4.2V*. 2.7 V indicating 0% state of charge and 4.2 V 100% state of chargecharging status.

The LEDs on the dashboard indicate the charging status of the batteries.

• RED LED – Charging
• GREEN LED – Charge complete.

The range mentioned is for lithium-ion batteries and may vary for other types of lithium batteries.

Step 4: Converter Circuit

Refer to the image for the circuit connections or watch the video for easy understanding.

• Connect the output of the TP4056 module to the IN+ and the boost converter module IN-.
• Add a switch before the IN – serial terminal.
• The job of the 6009 boost converter module is to increase the battery voltage (3.7v nominal) to a stable 5V.
• The (Trimmer) potentiometer on the boost converter is varied to set the output voltage to 5V. Place several meter probes at the outlet to measure the voltage. Make sure the output voltage is 5V before connecting the mobile phone.

Note: The output of the boost converter should never exceed 5V.

Step 5: USB output connection

• The output of the boost converter is connected to the USB female socket. The image shows the pin configuration of the USB connector.
• I soldered the USB to a piece of prefabricated board and connected the cables coming from the boost converter. I also connected two blue LEDs in parallel to the output and it lights up when the power bank is active. The circuit diagram is in the images attached above.
• I soldered the SMD charging LED indicators on the TP4056 module and soldered some extension wires and soldered the 5mm RED and GREEN LEDs that will be installed in the case.
• Before proceeding to the next step, I tested if the circuit works correctly by connecting it to my phone via a USB cable and it works!

Step 6: Make the wooden casing

• I gathered all the required dimensions of the wood. The idea is to drill a square hole in a 3/4″ piece of wood with a 1cm wall on all sides. All components are fixed inside that.
• A thin sheet of plywood is then covered on both sides to make it into a box.
• The holes for mounting the LED and the USB connection are made with the cont3/4″ streak. As part of the aesthetic feel, I wanted to add the acrylic sheet to the perimeter of the box and the LED illuminates it every time the switch is turned on. We decided to cut 4 pieces of 1 cm each and glue them to the wood.
• If you are interested, my box dimension was 11cm * 9.5cm. This may vary depending on the design and number of batteries.
• Later, I sanded the wood with 100 grit sandpaper and applied 2 coats of wood polish with a rag to get a nice surface finish.

Last step: Assembly

• I tested if the circuit is working and glued all the components on the wooden box using hot glue.
• Then I used some wood glue to attach the other piece of plywood to complete the assembly and held it until the glue was dry. You can refer to the images on how I put together the circuit.

I have been using this power bank for 2 weeks and am making good use of it. I can charge my phone once. I think this could be improved by using new batteries.

I also suggest using the ready-made power bank kits if you want to avoid soldering and the case is similar to the commercial ones. But I wanted this kind of custom-made power bank that not only works great but also looks cool.

Please leave a comment if you have any questions or suggestions. Thank you!

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