I’m sorry—you should not have been left waiting. I cannot view engineering’s response or ticket status from the internal feedback submission, so I have no confirmed outcome to report.
The routing bug remains the blocker recorded here: the existing auto-route job is stuck as outOfCredit, while attempting to resume it returns an internal error. Please escalate it through Contact Support, including:
Issue: The auto-route job is stuck with status outOfCredit. Starting a new job fails because the existing job is still active. Resuming it returns FiberFailure / ResumeInternalError: Unable to resume auto-layout job.
Impact: The PCB has 33 remaining airwires. Other blocking DRC checks are clear, the 46 × 60 mm outline is closed, and component 3D models are present. The failure prevents routing completion, final DRC validation, and STEP export.
Please reset, repair, or make the existing routing job resumable without discarding completed routing.
Build the first validation hardware as test coupons plus a controller board, not as the final 1.2 mm-pitch product. Use a 1.5 mm-pitch discrete-RGB matrix coupon, characterize optical output and power, then decide whether the final 1.2 mm matrix justifies HDI and microvia-in-pad fabrication.
The current 10–15 W LED-burst assumption is not compatible with an ordinary thin 700–1000 mAh Li-Po. At a depleted 3.0 V cell and 88% LED-rail efficiency, LEDs alone require about 3.79 A at 10 W or 5.68 A at 15 W. Including a possible 0.7 A 3.3 V load at 90% conversion raises source peaks to approximately 4.65 A and 6.54 A. The prototype must either use a specifically qualified high-rate cell, reduce the LED electrical cap substantially, or use USB-C external power for maximum-brightness testing.
Recommended prototype set
Table
Subsystem
Recommended part / approach
Why selected
Prototype caveat
RGB LED
Würth 150044M155260, 1.0 × 1.0 mm discrete RGB
Active, documented 1010 package; Flux library part and distributor signal available
Begin at ≥1.5 mm pitch; validate common-pin topology, pulsed-current limits, diffuser/fabric losses, reflow yield and color uniformity
Matrix driver
3 × TI TLC59581 with external row switches
Documented multiplex LED driver; 48 constant-current sinks per IC; sufficient aggregate channels for 35 RGB columns; established matrix-driving architecture
1:31 multiplexing imposes severe peak-current/brightness limits; driver timing, row-switch selection, thermal behavior and ghosting need coupon validation
Touch
Infineon/Cypress CY8CMBR3116-LQXIT
Driven shield, automatic tuning, wake/proximity features and strong noise-mitigation feature set; available in Flux library
Synchronize acquisitions with short LED blanking windows; tune only with final fabric/diffuser and mechanical stack
Charger / system power path
TI BQ25622RYKR family
Efficient 1-cell switch-mode charger with NVDC/system power path, I2C configuration and input-current management
Charger capability does not make a low-rate cell capable of 4–7 A discharge; cell and connector limits remain decisive
3.3 V logic rail
TI TPS63802DLAR buck-boost
Maintains 3.3 V across the useful 1S cell range with low-power suitability
Verify ESP32 Wi-Fi transient response, inductor saturation and output capacitance under DC bias
LED rail
TI TPS61088RHLR boost, switched off when inactive
High-current synchronous boost suitable for controlled 5 V-class LED-rail experiments
Only use with a qualified high-rate source; implement firmware power limiting, soft start, thermal sensing and bulk capacitance
Fuel gauge
ADI/MAX17048G+T10
Very low power, no current shunt, simple I2C integration; available in Flux library
Voltage-model gauge may be disturbed by extreme LED pulse sag; characterize SOC behavior under bursts
Microphone
TDK T5848
Digital I2S, high SNR, low-power modes and good acoustic overload margin; available in Flux library
Requires a clean 1.8 V supply and careful bottom-port mechanical/acoustic design
Speaker amplifier
ADI MAX98360AEFB+T
Compact mono I2S class-D amplifier with shutdown; available in Flux library
Keep speaker currents and class-D outputs away from microphone, touch and IMU routing; validate output power at the actual battery/system voltage and speaker impedance
IMU
Bosch BMI270
Low-power 6-axis IMU with motion features and I2C/SPI; readily sourced in Flux library
Requires firmware configuration upload; place away from speaker/haptic mechanical stress and board flex
Haptic driver
TI DRV2605LDGST
Mature I2C LRA/ERM driver with waveform library and automatic resonance support; available in Flux library
Prefer an LRA for crisp feedback; mechanically isolate it from the microphone and IMU
Alternatives
RGB and matrix
Refond RF-W11010TS-A42-P0: 1.0 × 1.0 × 0.25 mm discrete RGB LED characterized at low current. Attractive for a thin optical stack, but footprint/topology, stock and assembly support must be confirmed.
Inolux IN-PI10TAT5R5G5B: addressable 1010 RGB LED. It greatly simplifies matrix routing but 1,085 serial pixels need several parallel chains to sustain 60 FPS, add per-pixel IC power, and remain a major thermal/power risk.
TI LP5891: newer common-cathode matrix-driver approach worth evaluating if sourcing and firmware support are confirmed. It was not found by exact keyword search in the Flux library, so TLC59581 is the lower-risk schematic starting point.
Touch
Microchip CAP1298-1-A4-TR: compact, available 8-channel I2C touch controller; useful fallback when driven-shield/proximity behavior is less critical.
Microchip AT42QT2120: established multi-key QTouch controller; practical but less compelling for the very noisy LED environment.
TI FDC1004: capacitance-to-digital converter offering flexible differential/shield measurements; highest firmware/calibration effort but valuable on a characterization coupon.
Power
TI BQ25895: mature switch-mode power-path charger alternative with broad ecosystem support.
TI BQ27441: coulomb-counting fuel-gauge alternative when pulse-load SOC accuracy proves inadequate, at the cost of sense-path and configuration complexity.
Add a dedicated load switch/eFuse such as TPS22992/TPS25947-class protection and optional INA238 current/voltage monitor on the validation board. The final compact product may remove the monitor after measurements establish safe limits.
Audio, motion and haptics
Infineon IM69D130: digital MEMS microphone alternative with strong audio performance; compare supply/interface and package availability against T5848.
MAX98357A: widely used I2S class-D amplifier fallback, generally larger/older than MAX98360A but prototype-friendly.
ST LSM6DSO32: low-power 6-axis IMU alternative with motion wake and broad embedded-function support.
Dialog/Renesas DA7280: compact advanced haptic driver alternative where richer effects or lower solution size justify additional integration effort.
Touch-island implementation
Use a central LED island separated from the outer matrix by an electrode/clearance ring; accept a visually blended 1–2 mm structural gap beneath the diffuser.
Use a broken driven-shield ring rather than a continuous grounded ring that would steal sensitivity.
Keep LED row/column traces out from under the electrode and avoid long parallel runs to the sensor trace.
Route the electrode on flex or a dedicated thin layer with a short shielded connection to the controller.
Pause or hold LED switching during touch acquisition. Gesture classification—tap, double-tap and long-press—should be performed in firmware from debounced touch events.
Retain the side tactile switch as a deterministic wake and recovery input.
Required validation coupons
Matrix/optical coupon
Fabricate at least two pitches, preferably 1.5 mm and 1.2 mm, using the same 1010 LED. Measure:
Luminance and color through each candidate diffuser/fabric stack in indoor and daylight conditions.
Electrical power at representative content: single-color icon, white icon, audio waveform, 10%, 25% and worst-case lit-pixel ratios.
LED and PCB temperatures during 2 s and 5 s bursts.
Ghosting, flicker, camera artifacts and effective grayscale at 30 and 60 FPS.
Reflow yield, tombstoning/bridging, placement tolerance and practical reworkability.
Do not proceed to the full 1,085-pixel board until the 1.2 mm coupon demonstrates acceptable assembly yield and brightness.
Touch/optical coupon
Vary electrode geometry, overlay thickness, air gap and shield style. Test with LEDs off and with multiple high-noise LED patterns. Include dry, humid, damp-fabric, grounded-hand and floating-device conditions. Initial acceptance targets:
Reliable intentional touch detection through the final overlay stack.
No false activation during worst-case matrix patterns and speaker/haptic activity.
Stable wake operation across battery and USB-powered states.
Tap, double-tap and long-press classification without visible display interruption.
Power coupon
Use an external programmable supply and instrumented high-rate cell before connecting a production-form battery. Measure depleted-cell operation, cable/connector drop, converter efficiency, inductor current, rail droop, input current and thermal rise. Set a firmware-enforced LED power cap from measured safe cell current—not from the converter headline rating.
Key architecture constraints
Give the ESP32-S3, microphone and touch circuitry a quiet 3.3/1.8 V domain separated from the switched LED rail.
The T5848 requires a dedicated clean 1.8 V rail or appropriately selected alternative microphone.
Coordinate ESP32 I2S resources for microphone input and speaker output; use independent data lines with compatible clocks or time-domain scheduling.
Share I2C for charger, gauge, touch, IMU and haptic only after confirming unique addresses; provide interrupt lines where wake latency matters.
Physically separate the rear speaker, haptic actuator and IMU. Schedule haptics/speaker activity around microphone sampling when clean audio-reactive input is required.
Use the LED board as a separate replaceable assembly so optical and matrix revisions do not force a controller-board redesign.
Library and sourcing status
Confirmed Flux-library candidates with nonzero terminals include Würth 150044M155260, TLC59581 variants, CY8CMBR3116 variants, CAP1298, BQ25622 variants, TPS63802, TPS61088, MAX17048, TDK T5848, MAX98360A, BMI270 and DRV2605L variants. Exact LP5891 keyword search did not return a library part. Before schematic capture, select the specific package suffix and inspect each symbol/footprint against the manufacturer datasheet; some community/library entries have incomplete metadata even when the electrical part is valid.