Custom Electronics for Funko Pop

flux

I built the first-pass architecture and schematic foundation for the Blue AI Figurine PCB: ESP32-S3, USB-C, LiPo charger, 3.3 V buck regulator, I2S mic, I2S speaker amp, RGB LEDs, speaker connector, battery connector, and figure harness. I also created the project spec and power budget files, and wired the main power/audio/LED/USB nets.
Blocked: your account is currently out of available ACUs, so I can’t continue AI tool execution right now.
Remaining work:
  • Finish PCB board sizing/placement for the custom base.
  • Run ERC/DRC design review and fix any schematic issues.
  • Add firmware starter, bring-up, and regulatory/safety docs.
  • Verify final mechanical dimensions from the actual figurine/base before routing.
B

blueai

Continue and finish with the leftover 25 ACUs

flux

I’ll use the remaining budget to finish the highest-impact items first: size the base PCB, place components, add short architecture/bring-up docs, then run checks to see what remains.

flux

Done — I finished the high-impact remaining work: sized the PCB as an 80 mm circular 4-layer custom base, placed all physical components, and added project files for Architecture, Firmware Starter, Board Bring-Up Plan, and Regulatory & Safety Notes.
Open items:
  • Routing is not complete yet; the board still has airwires.
  • Auto-routing is currently blocked by a few helper/net/ground nodes that still need manual placement cleanup.
  • Before manufacturing, confirm actual base diameter, speaker size, LiPo dimensions, and wire path into the figurine.
Suggested next steps:
  1. Clean up the remaining auto-position helper nodes so routing can run.
  2. Route the PCB and verify no airwires remain.
  3. Add test points for USB_5V, VBAT, 3V3, GND, EN, BOOT, I2S, and LED data.
  4. Run a full ERC/DRC pass and fix manufacturing issues before export.
Clean helper nodes
Route the PCB
Add test points
Verify USB wiring
Optimize for manufacturing
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Files

Schematic

Layout

Preview

Project Specification — Blue AI Figurine PCB
Project Overview
Status: Draft. Custom electronics for a Blue AI figurine using an edge-to-cloud architecture: local hardware handles audio I/O, LEDs, sensing, power, and wireless connectivity; cloud or local server handles LLM, speech-to-text, and text-to-speech.
Intended Use
Prototype interactive collectible/desk companion for Mental Wealth Academy branding. The first PCB should prioritize reliability, debuggability, and safe battery charging over ultra-miniaturization.
What the Device Should Do
  • Wake/listen through a digital microphone.
  • Play voice/audio through a small speaker.
  • Connect to Wi-Fi/Bluetooth for cloud AI services and setup.
  • Animate RGB eye/orb LEDs based on state.
  • Charge from USB-C and run from a single-cell LiPo battery.
  • Provide debug/programming access for firmware iteration.
Main Features
  • ESP32-S3 module with Wi-Fi/BLE and native USB.
  • I2S digital microphone input.
  • I2S Class-D speaker amplifier output.
  • USB-C 5 V input, LiPo charging, 3.3 V logic rail.
  • Addressable LEDs routed into figurine/head.
  • Optional I2C/Qwiic-style expansion for IMU or future sensors.
System Architecture
Diagram



  
    
  
  
    
  





















Cloud AI / API
I2S Microphone in Head/Chest
MCU
I2S Class-D Speaker Amp
Micro Speaker in Base
RGB Eye/Orb LEDs
USB-C node_5V
LiPo Charger
1S LiPo
3.3V Regulator
Hardware Subsystems
  • Power: USB-C sink input, ESD/protection, LiPo charger, 3.3 V regulator, battery connector, power switch/test points.
  • Compute/Wireless: ESP32-S3 module, boot/reset controls, native USB programming.
  • Audio Input: I2S MEMS microphone, preferably located near head/chest opening.
  • Audio Output: I2S Class-D amplifier and 4–8 ohm micro speaker in the base.
  • Lighting: WS2812B/SK6812-style RGB LEDs for eyes/orb, connected by a small harness.
  • Expansion: small JST/Qwiic connector for I2C IMU or future sensors.
Interfaces and Connections
  • USB-C receptacle: 5 V input and USB D+/D- to ESP32-S3 native USB.
  • Battery connector: 1S LiPo JST-PH or compact equivalent.
  • Figure harness: 3.3 V, GND, I2S mic signals, LED data, optional I2C.
  • Debug: BOOT and RESET buttons; USB serial/JTAG via ESP32-S3.
Power and Runtime Expectations
Assume 500–1000 mAh LiPo. Active Wi-Fi/audio can draw several hundred mA, so first-pass runtime target is roughly 1–3 hours depending on LED brightness, speaker volume, and cloud-session duty cycle.
Power Tree and Power Budget

Table

RailLoadsEstimated TypicalEstimated Peak
3.3 VESP32-S3 Wi-Fi, mic, LEDs logic, sensors180–300 mA500–700 mA
VBAT / SPKClass-D speaker amp, charger/battery pathaudio-dependent0.5–1 A bursts
USB 5 VCharger + system load while plugged in0.5–1 A targetcharger-current limited
Power-path sizing assumption: use at least a 1 A-capable 3.3 V regulator/buck-LDO decision after exact audio/LED current is finalized. A simple LDO may overheat if sustained current is high; a buck regulator is safer for production.
Manufacturing and Assembly Expectations
  • 2-layer prototype PCB if possible; 4-layer if RF/audio layout or size constraints require it.
  • SMD assembly recommended for ESP32 module, USB-C connector, mic, charger, and amplifier.
  • Base-mounted PCB preferred over stuffing everything inside the head.
Firmware-Relevant Hardware Requirements
  • Arduino/PlatformIO starter firmware first, ESP-IDF later if production needs it.
  • Pins must cover I2S mic, I2S amp, RGB LED data, optional I2C, battery/charge status, BOOT, RESET, and USB programming.
Physical Design Expectations
  • Recommended board: circular or rounded custom-base PCB, initial target about 55–70 mm diameter until physical measurements are taken.
  • USB-C placed at rear/base edge.
  • ESP32 antenna at an outside edge with keepout.
  • Speaker opening/port in base.
  • Harness exits upward through figurine feet/stand.
Important Design Decisions
  • Use edge-to-cloud architecture rather than local LLM inference.
  • Use a custom base for battery, USB-C, speaker, ESP32, and charger.
  • Use digital I2S audio to avoid noisy analog preamps.
  • Use an ESP32-S3 module, not a bare ESP32 chip, to reduce RF risk.
Assumptions
  • Exact Funko/base dimensions are not yet measured.
  • Final speaker size and battery capacity are TBD.
  • Cloud AI service/API and firmware stack are not yet selected.
  • The image is product concept/reference artwork, not a precise mechanical drawing.
Change Notes
  • Initial architecture created from uploaded Blue AI figurine image and prior edge-to-cloud discussion.

  • Project Overview

  • Intended Use

  • What the Device Should Do

  • Main Features

  • System Architecture

  • Hardware Subsystems

  • Interfaces and Connections

  • Power and Runtime Expectations

  • Power Tree and Power Budget

  • Manufacturing and Assembly Expectations

  • Firmware-Relevant Hardware Requirements

  • Physical Design Expectations

  • Important Design Decisions

  • Assumptions

  • Change Notes