Custom Dual-Port 65W USB-C PD GaN Charger — Schematic + PCB Layout

TITLE: Custom Dual-Port 65W USB-C PD Charger — Schematic + PCB Layout (4 Stages) DESCRIPTION: We are developing VEGRIX, a budget dual-port USB-C PD charger for the UK, USA, EU and India market less than $5 BOM at 10k+ volume). PROJECT SCOPE: Dual USB-C ports, 65W total, dynamic power sharing (65W/0W, 45W/20W, 30W/30W) Simplified single-stage PFC flyback + dual buck architecture Efficiency target: 85–88% at full load Size: ~50 × 28 × 32mm Assembly: India CM optimized Regulatory: India BIS (IS 13779, IS 16047) + UK/EU CE (EN 60950-1) + USA FCC (Part 15 Class B) IC STRATEGY: Use budget ICs to hit less than $5 BOM: Southchip SC3057 or Injoinic IP2138 (primary controller) Silergy SY5238 (SR controller) Injoinic IP2738 (PD controller) Innoscience GaN + MCC MOSFET + CQAOS load FET Custom transformer from Feiteng/Xuange/Hang Tung 4-STAGE PROJECT: STAGE 1 (4–5 weeks): Schematic + BOM Deliverables: Schematic (Altium/KiCad), full BOM from live quotes, thermal/power calcs, compliance checklist Acceptance: less than $5 BOM confirmed, IC selection documented, transformer locked STAGE 2 (3–4 weeks): PCB Floorplan + Regulatory Review Deliverables: Floorplan, creepage/clearance validation, thermal strategy, assembly notes Acceptance: 6mm isolation verified, compliance checklist done, DFM clear STAGE 3 (5–7 weeks): Full PCB Layout Deliverables: Gerber files (DRC-clean), pick-and-place file, assembly drawing, design CAD Acceptance: All Gerbers verified, pick-and-place matches BOM, thermal paths documented STAGE 4 (5–8 weeks): First-Article + Testing + Production Readiness Deliverables: Test report (no-load, full-load, dual-port, USB PD, hipot), DFM report, production sign-off Acceptance: Voltages ±2%, efficiency 90%, dual-port balanced, hipot passed, all docs locked WHAT WE NEED FROM YOU: Your hourly rate OR fixed price for each stage Estimated timeline/hours per stage Portfolio: 2–3 previous charger designs (show schematics + PCB layout) Experience: dual-port OR complex flyback chargers, Altium/KiCad, India CM sourcing (optional) Any questions about scope DESIGNER MUST HAVE: 2+ charger/power supply designs in portfolio Altium Designer or KiCad proficiency India-based preferred (cost, CM familiarity, timezone) IP OWNERSHIP: All design files become VEGRIX Limited property upon final payment.