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There are two things to consider here, ESD and wireless signal strength. For ESD, it can be good to have a metal chassis surrounding the device going to ground to prevent discharges from humans reaching the device. The problem is the antenna's signal strength could be reduced from having a ground plane around it (if the metal chassis is around the whole ...


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Either mount the button to the chassis and use flexible wiring to the PCB, or mount the PCB so it is supported at one corner by the switch and can move sufficiently to absorb the maximum deformation that can be passed through the switch.


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If that 5v power supply with a barrel plug that itself has exposed metal meets electrical safety standards, then your metal-cased appliance will also be safe.


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If you bring AC mains into your product, then yes, you need a ground. If hot or neutral touched the chassis, then it would need to exit through the ground. By the sound of it you are using an AC-DC converter, so this would minimize testing. A good way of doing this is by using an external AC-DC converter. We did this on a product and avoided many of the ...


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The AC-DC section needs to meet applicable safety standards. One of those parameters is isolation between primary (AC) and secondary (DC). If the secondary is properly isolated, and has acceptable leakage that is below the limits allowed in the applicable standards, then it need not be earth connected. This is a complicated topic and I suggest you consult a ...


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