Custom Electronics for Funko Pop
Thought for 13 sec
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.
Worked for 12 mins 1 sec
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:
- Clean up the remaining auto-position helper nodes so routing can run.
- Route the PCB and verify no airwires remain.
- Add test points for USB_5V, VBAT, 3V3, GND, EN, BOOT, I2S, and LED data.
- 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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Board Bring-Up Plan — Blue AI Figurine PCB
Prerequisites
- Multimeter, USB-C current meter, oscilloscope if available, current-limited supply, USB cable, LiPo simulator or protected single-cell LiPo.
- Firmware reference: see the firmware starter project file.
- Start without the LiPo connected for first USB power checks unless using a current-limited battery simulator.
1. Visual Inspection
- Check USB-C J1, ESP32-S3 U1, charger U4, buck regulator U5, amplifier U3, mic U2, and LED orientation.
- Confirm no solder bridges around USB-C, ESP32 module pads, U5 switch node, and MAX98357A pins.
- Verify J2 battery polarity and J4 speaker polarity.
2. Power Rail Verification
Table
| Rail | Source | Expected Voltage | Measure At | Current Limit | Pass Criteria |
|---|---|---|---|---|---|
| USB_5V | J1 USB-C | 5.0 V | J1 VBUS / U4 VDD | 100 mA initial | 4.75–5.25 V, no overheating |
| VBAT | J2 / U4 | 3.0–4.2 V | J2 pin 1 / U4 VBAT | 100 mA initial | Follows LiPo/simulator voltage |
| 3V3 | U5 TLV62569 | 3.3 V | U1 3V3 / U2 VDD / U3 supply | 150 mA initial | 3.2–3.4 V before firmware load |
| GND | Common return | 0 V | Any GND test point/pin | — | Continuity across connectors |
3. First Power Procedure
- With power off, measure resistance from USB_5V to GND and 3V3 to GND; investigate very low resistance before applying power.
- Apply USB-C power through a current-limited source or USB current meter.
- Confirm USB_5V and 3V3 appear and current remains reasonable.
- Connect LiPo/simulator and verify VBAT and charging behavior.
- Check U5 switch node only with an oscilloscope probe and short ground spring if available.
4. Programming and Boot
Table
| Interface | Signals | Expected Result |
|---|---|---|
| USB native/programming | USB_D_PLUS, USB_D_MINUS, ESP_BOOT, ESP_EN | ESP32-S3 enumerates when bootloader mode is entered |
| BOOT/RESET buttons | SW boot/reset network | BOOT low during reset enters flashing mode |
5. Functional Validation
Table
| Test | Components | Expected Result |
|---|---|---|
| Wi-Fi scan | U1 | ESP32 reports visible networks |
| RGB LEDs | D1, LED1 | Both LEDs show commanded colors |
| Microphone capture | U2 | Non-zero I2S samples and changing level when speaking |
| Speaker output | U3, J4 | Test tone audible at low volume first |
| Figure harness | J3 | Continuity and correct LED/data/power pins |
| Battery charge | U4, J2 | Charge current matches R6 program setting within tolerance |
6. Open Hardware Checks
- Add or identify convenient probe points for USB_5V, VBAT, 3V3, GND, ESP_EN, ESP_BOOT, I2S_BCLK, I2S_WS, and LED_DATA_MCU.
- Confirm final LiPo capacity, max charge current, and enclosure thermal behavior.
- Verify USB data wiring and bootloader entry before ordering production boards.
Prerequisites
1. Visual Inspection
2. Power Rail Verification
3. First Power Procedure
4. Programming and Boot
5. Functional Validation
6. Open Hardware Checks
