I have a PlayStation Gold wireless headset, for chatting with people I play video games with. It usually recharges via a USB cable but I wanted a recharging stand for it, so that the USB connector does not suffer from wear-and-tear and I don’t have to worry about managing yet-another-USB-cable.
More pictures below
The stand itself is made of 9mm thick clear acrylic plastic, laser cut and laser etched by Ponoko. I used copper foil tape to make a connection from a DC barrel jack to the headset. The headset has two patches of conductive velcro that connects with the copper foil tape. Inside the headset, I installed a simple lithium battery recharging circuit. There is a LED that will glow red during recharge, and glow green when the battery is full.
The circuit is made with spare parts soldered to a piece of protoboard. Here is a circuit diagram:
The circuit itself is protected from all sorts things. Self resetting PTC fuses prevent damage to the power supply and the circuit. A schottky diode to prevent damage from reverse polarity. A zener diode provides a crude over voltage protection. A TVS diode (not shown in circuit diagram, sorry) is used to protect against static electricity. One way that I could’ve improved the circuit is to use a full bridge rectifier.
In simple words, I can’t break it by placing it on the stand backwards, or by using the wrong wall-wart, or by short circuiting anything, or by having too much static electricity from my hair.
If you are interested, here is the vector file for the laser cutting and etching (click here)
The laser cutting and engraving is quite expensive, but if you wanted to do this cheaply, you can always use cheap materials like wood.