ESP32 Flex Sensor Board Design

flux

0:04

Work done
  • Removed duplicate legacy schematic blocks and kept a single production path built around IC2, U5, J9, U6, U3, and U7
  • Removed alternate/duplicate parts U1, U2, J1, IC1, J2, U4, U8, J7, J8, SW1, SW2, J4, J5, and J6
  • Normalized USB net names to USB_DP and USB_DN, retained the 3-pin haptic connector scheme on J11 and J12, and added explicit no-connect markers for intentionally unused pins on IC2, U5, U7, U3, and J9
  • Verified key power and interface rails: VBUS -> U5 -> VSYS -> U3 -> 3V3, battery rail VBAT to J10, USB native data from J9 through U6 to IC2, and boot/reset pull networks on SW3, SW4, R17, and R8
  • Set the layout to 160 mm x 100 mm, 4-layer, with inner layer 2 as ground plane and inner layer 3 as a power-oriented plane, plus baseline board rules of 0.15 mm minimum trace width, 0.15 mm minimum keep-out, and 0.2 mm board inset margin
  • Updated and saved project notes in Design Notes
Success criteria review
  • ✅ The schematic was substantially cleaned up and duplicate major circuits were removed
  • ✅ Power, USB, and ESP32 boot/reset circuitry were reviewed and consolidated into a single retained implementation
  • ✅ Production MPN metadata was improved for key ICs including U3 and U7, and all current parts have footprints assigned
  • ✅ The PCB layout size, stackup, and core board rules are now defined
  • ❌ The layout is not yet fully routed: DRC still reports 82 airwire errors
  • ❌ ERC still reports unresolved floating capacitor pins on C1, C7, C8, and C16
  • ❌ I could not complete placement optimization or trace routing because the available toolset in this run does not include a placement or routing mutation tool, so I cannot finish the remaining PCB connectivity from here
Next steps The design is materially cleaner and constrained, but it is not yet production-ready because routing and a few remaining schematic cleanup items are still open. If placement and auto-routing tools are made available in a follow-up run, I can finish the remaining airwires, resolve the last floating caps, and close the final ERC/DRC gap.
Clean up duplicates
Review critical circuits
Fix ERC/DRC issues
12 days
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ESP32 Flex Haptic Board thumbnail
Beginner-friendly battery-powered ESP32-S3 board with USB-C charging/programming, LiPo power-path charging, three flex sensor inputs, one I2C IMU, and two haptic driver outputs.

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$15.67–$15.84

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$0.32

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