Thruster Arc Core V1
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Current state from this session:
- The project already has the core component set added for THRUSTER ARC CORE V1.
- Schematic wiring was only partially completed; several nets still need finishing before layout/routing can be trusted.
- Because wiring is incomplete, the likely required sequence is schematic completion → ERC → PCB placement → routing → DRC, not layout-only.
What remains before auto-layout can safely run:
- Finish critical schematic wiring: ESP32 USB/UART/boot/reset, LED chain, touch sensor/electrode, charge-status signals, battery monitor, test pads.
- Verify footprints/packages for passives, connectors, LEDs, ESP32 module, USB-C, and mounting holes.
- Define/confirm the circular board outline and center cutout.
- Run placement, then routing, then DRC and fix violations.
Once ACUs are available, I can inspect the live board state, determine whether placement/routing/both are needed, and apply the auto-layout results automatically.
Finish schematic wiring
Run ERC review
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Project Specification — THRUSTER ARC CORE V1
Project Overview
- Status: Draft
- Device: Professional circular PCB for a wearable smart device called THRUSTER ARC CORE V1.
- Core concept: ESP32-C3 BLE controller, 16 addressable RGB LEDs in a circular ring, Li-ion battery charging, USB-C programming/charging, Qi receiver connector, NFC antenna connector, and wearable-focused mechanical constraints.
Intended Use
- Wearable prototype / product-intent electronics core.
- Designed to fit a circular enclosure with diffuser windows over the LED ring.
- Assumes low-voltage battery operation only; no mains power on-board.
What the Device Should Do
- Run ESP32-C3 firmware over BLE.
- Drive 16 addressable RGB LEDs arranged symmetrically in a ring.
- Charge a 3.7 V 500 mAh Li-ion/LiPo cell from USB-C.
- Accept optional Qi receiver power through a connector.
- Provide NFC antenna connector access.
- Support USB programming, boot/reset controls, test pads, and a programming header.
- Provide a capacitive touch power button and a status LED.
Main Features
- Circular 58 mm outer diameter PCB with 32 mm center hole.
- 0.8 mm PCB thickness, black solder mask, ENIG finish.
- Four M2 mounting holes.
- ESP32-C3-WROOM-02 module.
- 16 addressable RGB LEDs under diffuser windows.
- USB-C connector for programming and charging.
- Battery connector for 3.7 V 500 mAh Li-ion/LiPo cell.
- TP4056-class linear charger, battery protection, 3.3 V regulator.
- Qi receiver connector and NFC antenna connector.
- Reset button, boot button, status LED, test pads, and programming header.
System Architecture
Diagram
Hardware Subsystems
Controller
- ESP32-C3-WROOM-02 selected per user requirement.
- Native USB serial/JTAG on ESP32-C3 is assumed for USB-C programming.
- Boot/reset support required: GPIO9 boot button and EN/CHIP_PU reset circuit.
- Antenna keepout required on all copper layers under/around module antenna.
LED Ring
- 16 addressable RGB LEDs, equally spaced around annulus.
- Assumption: 3.3 V-compatible addressable LEDs will be selected where possible to avoid a 5 V LED rail and level shifter.
- LED data routed from ESP32-C3 through a series damping resistor.
Power and Charging
- 1S Li-ion/LiPo battery, nominal 3.7 V, 500 mAh.
- USB-C sink mode requires separate 5.1 kΩ pull-downs on CC1 and CC2.
- TP4056-class charger requires charge-current programming resistor; charge current should be conservative for 500 mAh cell.
- 3.3 V regulator must handle ESP32-C3 RF current plus LED current.
- Battery protection IC required unless the cell already includes protection; design will include a protection device/footprint by default.
Wireless / External Antennas
- BLE via ESP32-C3 module antenna.
- NFC antenna connector included as an external interface; firmware/use-case details TBD.
- Qi wireless charging receiver connector included as 5 V input.
User Interface / Debug
- Capacitive touch electrode for power button behavior.
- Status LED.
- Reset and boot buttons.
- Test pads and programming header.
Interfaces and Connections
Table
| Interface | Purpose | Notes |
|---|---|---|
| USB-C | 5 V power + USB programming | Sink-only, USB 2.0 D+/D- to ESP32-C3 native USB pins |
| Battery connector | 1S Li-ion/LiPo | 500 mAh nominal |
| Qi receiver connector | Optional 5 V charging source | Needs polarity and connector choice confirmed |
| NFC antenna connector | NFC external antenna | Exact NFC IC/reader function TBD; connector-only unless NFC IC is added |
| Programming header | Debug/programming access | Pinout to be defined during schematic |
| Test pads | Manufacturing and bring-up | 3V3, GND, USB D+/D-, EN, BOOT, LED data, battery voltage |
Power and Runtime Expectations
- Battery: 3.7 V 500 mAh nominal.
- Charging: USB-C and optional Qi receiver input.
- Runtime depends strongly on LED brightness; 16 RGB LEDs at full-white can exceed the capacity of a small wearable battery.
- Firmware should limit LED brightness/current for wearable runtime and thermal comfort.
Power Tree and Initial Power Budget
Diagram
Table
| Load on 3.3 V | Typical Estimate | Peak / Design Note |
|---|---|---|
| ESP32-C3 module | 80–160 mA active RF | 350–500 mA short RF peaks |
| 16 addressable RGB LEDs | firmware-limited | Worst-case full-white can be hundreds of mA to ~1 A depending LED type/current limit |
| Status LED / passives | <5 mA | firmware-controlled |
| Touch/debug overhead | <1 mA | negligible |
Initial sizing target: Use a 3.3 V regulator rated at least 600 mA if LED brightness is firmware-limited; consider 1 A if the chosen LEDs can draw high current. Full-white LED operation should be limited in firmware for battery life and thermal reasons.
Manufacturing and Assembly Expectations
- PCB: 58 mm circular outer shape, 32 mm circular center cutout, 0.8 mm thickness.
- Finish: ENIG.
- Solder mask: black.
- Mounting: 4x M2 holes, symmetric.
- Design target: manufacturing-ready Flux design with BOM, pick-and-place, and Gerber export after schematic/layout/routing are validated.
- KiCad export requested by user; export readiness depends on Flux project completion and available export flow.
Firmware-Relevant Hardware Requirements
- Define GPIO map for LED data, status LED, capacitive touch, boot/reset, USB D+/D-, battery sense if added, and optional NFC/Qi status pins if used.
- ESP-IDF or Arduino core for ESP32-C3 can be supported after pin map is finalized.
- Include safe LED brightness defaults to protect runtime and battery current.
Physical Design Expectations
- Circular annular PCB: 58 mm OD, 32 mm center hole.
- ESP32 generally near center/edge compromise; module antenna must face an open board edge/keepout region, not copper-filled under antenna.
- LEDs equally spaced around the annulus and aligned to diffuser windows.
- USB-C aligned to enclosure opening.
- Battery connector at rear.
- Large ground plane and wide power traces.
- Decoupling capacitors close to IC power pins.
Important Design Decisions
- Use ESP32-C3-WROOM-02 module rather than bare ESP32-C3 chip to reduce RF design risk.
- Use native USB-C programming instead of a separate USB-UART bridge.
- Use 4-layer PCB by default because this is a compact wearable with USB, RF antenna keepout, power distribution, and dense annular LED placement.
- Treat full-brightness LED current as a firmware-limited condition unless the user requests maximum brightness operation.
Assumptions
- LEDs will be chosen to support 3.3 V data and battery-friendly current, or a level-shifter/power rail will be added if a 5 V LED type is selected.
- USB-C is device/sink-only; no USB-PD negotiation.
- Qi receiver provides regulated 5 V into the charger input.
- Battery protection will be included on-board unless the final battery is confirmed protected.
- NFC requirement currently means connector access; a full NFC reader IC is not included unless requested.
- Exact enclosure datum for USB-C, diffuser windows, and battery connector orientation is not yet provided.
Change Notes
- Created from pasted requirements on 2026-07-11.
- Project renamed to THRUSTER ARC CORE V1.
Project Overview
Intended Use
What the Device Should Do
Main Features
System Architecture
Hardware Subsystems
Controller
LED Ring
Power and Charging
Wireless / External Antennas
User Interface / Debug
Interfaces and Connections
Power and Runtime Expectations
Power Tree and Initial Power Budget
Manufacturing and Assembly Expectations
Firmware-Relevant Hardware Requirements
Physical Design Expectations
Important Design Decisions
Assumptions
Change Notes
