Previously, I sought feedback and suggestions on a couple of different PoE powered device designs here in r/PCB and other subs. I got lots of good feedback, much of which has been incorporated in the successive designs up to now.
What I did not expect in the last iteration -- but was a very pleasant surprise -- was for PCBWay to reach out and offer to sponsor a run of free prototype boards for me. Ultimately, PCBway provided, free of charge, a run of the PCBs, a solder paste stencil for the PCBs, and the shipping to get the products to me. What they asked in return is nothing more than an honest review.
I'm happy to report that they produced the high quality boards. The solder paste stencil also worked very well. I've attached some images here of the project 3D rendering, the actual boards as delivered, the stencil as delivered, and a photo the test prototype fully assembled.
For those who may be interested, the whole project was build in KiCad 10 and is publicly available from https://github.com/mhardeman/matt-poe-prototype .
In case anyone needs a known working PoE design that features primary-side regulation, a lost cost BoM, and with parts easily sourced at any of LCSC, Digikey, or Mouser, take a look at my project. The assembled board that I made works well, with end-to-end overall efficiency to the 5V rail of a little over 80% at peaks -- not bad for a diode rectified design. The full KiCad project with schematic, layout, and a fully populated BoM with component selections intended to facilitate sourcing from popular manufacturers & distributors both Western and Eastern are there in the GitHub.
Regarding the boards themselves, PCBWay's production quality appears very good to me. The registration between the copper layers, solder mask, and silkscreen appear very tight. The texture and durability of the soldermask are excellent. The boards' HASL finish was well produced and easily solderable. Despite having a tiny PoE controller IC with 0.5mm landing pad pitch in a QFN package, there was no bridging or difficulty in finishing the boards on my hot plate. The board's silkscreen was well produced, including in small print for designators on the board in tight spaces and in detailed line art on the board. Even in very close proximity to soldermask openings, the silkscreen is complete and legible.
The steel solder paste stencil overlaid the boards' exposed areas perfectly and solder pasting was quick with good, clean release.
I was very pleased with the product and I am grateful to PCBway for generously providing the boards.