Many thanks to all my new supporters!
I was thinking a lot about how to increase output current.
In my opinion, USB-BC (USB Battery Charging 1.5A) and USB-PD (up to 100 W) are not that common that it would be okay to increase costs/size for people having it, especially in a first version.
My focus was on USB 3.0 that would allow 900mA but only after the device requests for it. Hope I not overlooked it, but I was not able to find a valid answer how to request 900mA when having a USB 2.0 device, all ends in conclusion that I must have native USB 3.0 support on device then.
Some of the PCs I tested here did active limiting to 500mA when using the USB 3.0 port. It depends on the Host chip, some are more tolerant. It seems to be no problem to shortly get more (I think because mobile USB hard drives need enough initial current to run).
The answer will be USB Type-C, here the concept is nice, they separated USB transmission protocol and power setup mechanism: Up to 15W, there is no need of using USB PD specification, the output current is configured by a simple passive resistor setup for both, the cable and the device. This allows using USB 2.0 together with 15W. When needing more than the 15W again, the USB PD protocol must be implemented.
Yes, I would really like to add this hidden switch to enable more power for people that know what they do, but the final hardware design does not allow this.
I calculated/simulated/tested all for 500mA now, increasing to 900mA or more would be a significant difference and requiring other components.
So sorry, you have to wait for the next version that hopefully will come one day.
Hope your project will be successful but is not looking that great at this point in time.
Your are right, it is not looking that great for the moment. There are too many people on world, that seems not knowing about my project.
Yes, your PCB case style is really cool, never seen this before.
Good luck to you.
Did you look at urethane cast, vacuum forming or off the shelf enclosures?
The truth is, I did not. There are online supplier that are focused on injection molding for smaller prototype quantity. They use aluminum molds that are much better to process automatically. When calculating the total costs for 500 samples, it ends in something between $2 and $5 for small cases. This is still a lot for something that will cost some little cents for larger amounts, but it was okay for me.