Resized the PCB to 100 × 75 mm, 4-layer, to add routing margin while staying within a common prototype size.
Re-placed the layout so DS1 remains top-side, while U4/MAX30102 and U5/MLX90614 are on the bottom wrist side, close together near the center beneath the OLED.
Kept the ESP32-C3 antenna at the edge facing outward, with USB-C, battery connector, switch, and power parts arranged away from the sensor cluster.
Success criteria review
✅ Skin-touch sensors are now bottom-side and centered under the OLED.
✅ OLED remains top-side and antenna placement was preserved at the board edge.
❌ Routing is not complete: the latest validation still reported 87 airwires and 12 overlapping-copper issues before the final re-placement, and I could not continue to reroute/validate further.
❌ Manufacturing export files were not generated, because export should only happen after DRC is clean.
Next steps
Run routing cleanup/autorouting next, then re-check DRC until airwires and copper conflicts are cleared.
After DRC is clean, generate the Gerber, BOM, and pick-and-place manufacturing package.
Board remains a 58 mm x 42 mm rounded rectangle on a 2-layer stackup.
Baseline JLCPCB trace rules were applied: 0.25 mm default trace width, 0.18 mm minimum trace width, and 0.18 mm board inset.
Component placement was re-optimized for wearable orientation and routing clearance.
ESP32-C3 module is oriented with its antenna facing the bottom edge.
OLED FPC remains at the top visible edge.
MLX90614 remains on the outward top edge.
MAX30102 was forced to the bottom/wrist side and centered via layout rules.
USB-C, ESD, charger, regulator, battery connector, switches, IMU, and test pads were kept in functional zones.
Validation status
Missing footprint check: passing.
Invalid layer check: passing.
Floating copper check: passing.
Electrical checks for floating pins and missing power: passing.
Blocking layout checks still fail:
87 airwires remain.
13 overlapping-copper errors remain.
Manufacturing readiness
The design is not ready for a JLCPCB release package yet because routing is incomplete and copper overlaps remain. Gerber/pick-and-place/BOM manufacturing outputs should be generated only after routing and keepout enforcement are completed and the DRC is clean.
Remaining work
Complete routing for all remaining airwires.
Resolve overlapping copper errors.
Add/verify physical copper keepouts manually for:
ESP32 antenna bottom keepout: 15 mm clear region.
MAX30102 wrist optical aperture: no copper/plane/mask under sensing area; optional guard ring.
MLX90614 aperture and thermal isolation: clear optical path and 6–8 mm clearance from heat sources.
Re-run DRC/ERC and export JLCPCB manufacturing outputs once clean.