I pulled the key decisions out of the three files.
This project is now framed as a battery-first, local-first furnace filter monitor that measures actual differential pressure across the filter, updates filter life in quiet bucketed steps, and keeps working even if cloud services are unavailable
Locked product direction
Single battery-powered product
Pressure sensing is the only continuous sensing task
Thread / Matter is primary
BLE is allowed for provisioning/service
Wi-Fi stays as fallback
External antenna is retained
No Ethernet
No USB
No external power connector
No screen; at most a simple red status LED
Power and battery
Baseline pack is 3 x D alkaline
4 x D is allowed as a contingency if packaging or runtime margin requires it
Service model is designed around battery replacement without losing state
The target service interval is about 24 months, with 36 months as a stretch goal if testing supports it
Mechanical / sensing constraints
Use static pressure pickups and tubing
Mount on the return side / pre-blower side
Use magnetic mounting
Keep the pressure path mechanically isolated
Protect the sensor zone, antenna path, and pressure ports from battery service disturbances
Security / product behavior
Core behavior must remain offline-capable
Secure onboarding, secure local comms, authenticated OTA
No open production debug
Preserve identity, history, last known state, and queued events across battery swaps
Biggest unresolved risks
Scope creep into a broader smart-home product
Battery-life impact from keeping Wi-Fi fallback in all units
Final enclosure and battery geometry around the 3 x D / 4 x D decision
Antenna routing and tubing routing in the final enclosure
Highest-value next steps from the files
Freeze the comms boundary: Thread/Matter primary, BLE provisioning, Wi-Fi fallback
Freeze enclosure volume and battery placement
Freeze pressure sensor + tubing/port design
Convert the plan into schematic blocks, board zoning rules, EVT BOM, firmware backlog, and app backlog
This matches the direction you typed earlier almost exactly: single 4-layer board, pressure sensor zone first, RF at edge, external antenna, battery-first power tree, secure element onboard, no Ethernet/USB/external power, and battery servicing that does not disturb sensing or RF
If you want, I can next turn this into one of these:
Documents are markdown text files which describe project goals, capture details, or even simulation outputs.
Assets
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PCBWay 4 Layer Stackup
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