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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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
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
| Rail | Loads | Estimated Typical | Estimated Peak |
|---|---|---|---|
| 3.3 V | ESP32-S3 Wi-Fi, mic, LEDs logic, sensors | 180–300 mA | 500–700 mA |
| VBAT / SPK | Class-D speaker amp, charger/battery path | audio-dependent | 0.5–1 A bursts |
| USB 5 V | Charger + system load while plugged in | 0.5–1 A target | charger-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
