Custom USB Charging & Integration Services

From concept to production, our UK engineering team designs and manufactures tailored charging and data systems for any application.

What We Do

01.
Four USB charge and sync circuit boards integrated into a metal chassis

🔌 Integrated Electronics

Custom-engineered USB charging, data, and power distribution systems.
Built around our proven Chargebus modules, we deliver scalable architectures for mobile and fixed installations — providing simultaneous fast charge and data transfer across USB-A, USB-C, and Ethernet systems.
02.
Custom electronics and power modules integrated into a rugged protective case

🧰 Protective Case Integration

We design and build complete electronic systems into rugged enclosures such as Peli, Explorer Cases, and custom flight cases.
Perfect for field use, these units combine power management, cooling, and cable routing with robust protection — keeping devices safe, organised, and ready to deploy anywhere.
03.
Custom black metal electronics enclosure with connector cut-outs

🧩 Custom Enclosures & Assemblies

Mechanical design and precision assembly to match your use case — from rackmount panels and wall-mount enclosures to portable trolleys and modular charging bays.
We optimise layout, thermal management, and cable routing for durability and ease of service.
04.
Ethernet switch and network equipment integrated into a custom enclosure

🌐 Network & Data Systems

Integration of Ethernet, switching, and Wi-Fi components alongside USB charging electronics.
Ideal for environments where devices must charge, connect, and communicate simultaneously — such as education, field service, and industrial automation.
05.
3D render of a custom electronics PCB prototype

⚙️ Prototype Development

Rapid prototyping, functional testing, and pre-production builds handled in-house.
We deliver working samples and proof-of-concept systems quickly, allowing you to validate design, fit, and performance before committing to volume production.

  Every project is engineered, assembled, and tested in the UK — ensuring quality, traceability, and full technical support.

Case Study

Smart Insole Charging Case

Sports Technology Integration

Client: Sports technology manufacturer supplying smart performance insoles to professional football clubs.

Objective: Develop a compact, portable charging and data management system capable of charging and syncing 20 smart insoles within the same footprint as their existing unit.

Challenge: The client’s large, multi-board charger was too bulky for training-ground use. They needed a smaller, integrated solution with full-speed USB charge and sync, while maintaining reliability and ease of transport.

Solution: Chargebus engineered a custom 10-port USB charging and sync system housed in a rugged protective case. We designed a bespoke PCB that condensed their large-format board into a compact single-board layout, optimising cable routing, thermal management, and power distribution.

  • Charge, store, and sync up to 20 smart insoles
  • Custom PCB charging and data circuit design
  • Integrated USB sync for firmware and analytics
  • Rugged, portable case with internal power and cooling
  • Fully engineered, assembled, and tested in the UK

Outcome: The new system replaced several larger chargers with one transportable case, reducing setup time and improving reliability for the client’s technicians and players.

Open rugged charging case designed for multiple smart insoles
3D render of the custom PCB assembly for a smart insole charging case

Start Your Custom Project

Let’s build a charging system around your requirements.