High-Current SMPS Design for LED Wall

@tshibsamuel477

Hi there, I carefully read your project, and it aligns perfectly with my experience in power electronics and high-current SMPS design. I can help you design a reliable, high-efficiency 300W (5V @ 60A) supply suitable for continuous industrial operation in LED video wall applications. I’m Samuel Tshibangu, a mechatronics engineer with strong experience in PCB design, power supply architectures (SMPS, synchronous rectification), and high-current layout optimization. I’ve worked on similar designs involving AC-DC conversion, protection circuits, thermal management, and manufacturable power boards, so I can deliver a robust and production-ready solution. For your case, I would evaluate LLC or Half-Bridge topology (depending on efficiency, cost, and thermal constraints) and ensure proper transformer design, EMI considerations, current handling, and protection mechanisms. My focus is always on reliability, efficiency, and clean high-current PCB routing. I can deliver the full schematic, PCB layout, transformer design, Gerbers, BOM, and support during prototyping and debugging if needed. Feel free to send me a message. Best regards, Samuel Tshibangu

@abdurRafiqM

HI, I am an experienced electronics and PCB Design engineer, specialised in use of ECAD software such as Altium Designer, KICAD, EasyEDA, etc. for the the design of electronics and PCB. I will design your projects to meet your Requirements and the industry standard. I do all kinds of circuits such as Power delivery circuit, Sensor Integrated Circuits, wireless control, MCUs etc. I will deliver the following. The Schematics for your Design The PCB for the design Bill of materials(If needed) Gerber, Pick and Place and other manufacturing and assembly drawings needed. Full Support and consultancy till the project is done. Kindly send me message for my previous designs and also so we can discuss further on your project I look Forward to working with you. Best Regards, Abdur-Rafiq

@lilyb30

I am an experienced power electronics engineer with a strong background in designing high-current SMPS. Based on your specifications, I can provide a solution that meets your needs for efficiency, reliability, and safety. Key Design Elements: Input: 90–265V AC with industrial-grade input protection. Output: 5V @ 60A (300W continuous) with low ripple, stable under dynamic load. Topology: I will propose a topology (LLC, Forward, or Half-Bridge) that ensures optimal efficiency and reliability for your application. Mechanical Design: Compact metal enclosure with optimized airflow and thermal management. Electrical: Efficiency >90%, synchronous rectification, proper current sharing/distribution, and suitable connectors for 60A output. Protection: OVP, OCP, SCP, and thermal protection. Deliverables: Annotated schematic, transformer design (if applicable), optimized PCB layout, Gerber files, BOM with part numbers, and assembly drawing. Experience: I’ve designed high-power SMPS for industrial, medical, and commercial products, focusing on efficiency and thermal management. In previous projects, I’ve handled designs up to 500W and offered prototype debugging support. I look forward to discussing how I can help bring your digital LED video wall project to life. Best regards, Lily

@amitdebnath251

Hii, I am an experienced electronics and PCB design engineer with a proven track record in high-power SMPS (>200W) and industrial-grade circuit design. I specialize in PCB layout optimization for high-current paths, EMI compliance, and thermal management, which are critical for your LED video wall application. My Approach Input Stage: Design with 90–265V AC universal input, including surge suppression, EMI filtering, and industrial-grade protection. Output Stage: Deliver 5V @ 60A (300W continuous) with low ripple and stability under dynamic LED loads. Implement synchronous rectification for >90% efficiency and proper current distribution. Topology: Recommend LLC resonant or half-bridge forward converter for efficiency, reliability, and compactness. Mechanical & Thermal: Compact metal enclosure with airflow design, ensuring safe operation in continuous environments. Protection: OVP, OCP, SCP, and thermal shutdown integrated for robust reliability. Deliverables Full annotated schematic Transformer design (if required) Optimized PCB layout with wide copper pours and via stitching for 60A output Gerber files ready for manufacturing Detailed BOM with exact part numbers Assembly drawing and thermal/current path documentation Support for prototype debugging I am confident in delivering a compact, efficient, and reliable SMPS solution tailored to your LED wall application. Best regards, Amit Debnath