Quick progress report: things are moving forward toward production. All parts for building the thermally improved #LiFePO4wered/USB base boards are at the CM:

I also received all production parts for the #LiFePO4wered/Pi add-on board, updated my prototypes with the production components and ran a load test. I used a Pi 3, with active SSH connection over Ethernet, an extra USB WiFi dongle, and all 4 cores at 100% usage. I took a thermal image out of curiosity:

Yikes, that sucker gets hot! You can bake an egg on that. :)

I'm happy to report that everything ran stable and the 5V didn't sag even under high load like this. As explained before, you can't use the #LiFePO4wered/Pi as a UPS under continuous conditions like this because the Pi takes more current out of the battery than the charger puts in, but it proves the power supply is solid and will be able to buffer high usage bursts just fine.

Next step is to lay out a panel for the #LiFePO4wered/Pi add-on board and order it.