Smart Compression Device Design

flux

0:07

Work done
  • Updated the PCB layout outline to 52 mm x 31 mm with 1 mm corner radius and tightened edge keep-out / inset constraints.
  • Replaced the layout stackup baseline from the prior 4-layer setup to a 2-layer baseline, which is closer to the wearable target.
  • Audited the current schematic and layout state for the major wearable subsystems: U1, U2, U3, U4, U5, U6, U7, and J2.
  • Confirmed the layout still exceeds the target envelope and that the project remains heavily incomplete electrically and physically.
Success criteria review
  • ❌ Schematic is fully organized into clearly labelled functional blocks with consistent naming.
  • ❌ Unnecessary connectivity artifacts are removed.
  • ⚠️ PCB setup now matches the requested 52 x 31 mm outline more closely, but flex-specific material/profile constraints could only be approximated with the available stackup templates.
  • ❌ Components are not yet repositioned into a compact, routing-ready placement; current aggregate bounds are still about 68.57 mm x 70.63 mm.
  • ⚠️ I documented the major residual risks, but the design is not yet in a review-ready cleaned state.
Next steps The project still needs a safe net-intent pass before cleanup: resolve the large set of floating pins on U1, U2, U3, U4, U5, U6, U7, and J2, then reduce portals/grounds, rename anonymous nets, and manually re-place the layout. I cannot complete the requested full cleanup and compact placement with the current project state because symbol movement / schematic visual reorganization and PCB component re-placement are not directly executable here, and further destructive net cleanup would risk breaking the architecture before those unresolved pins are classified.
Tighten flex rules
Recluster by function
Clean schematic artifacts
Review remaining risks
28 days
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    CombatTrack Smart Sleeve

    CombatTrack Smart Sleeve thumbnail
    BLE wearable flex PCB with LiPo charging, PPG plus skin temperature, 3-channel EMG, IMU, and piezo impact sensing for a smart compression sleeve

    Properties

    3.3V

    72h operation from 100mAh LiPo, target average current <=1.39mA

    BLE 5.x

    52x31mm single-layer 0.1mm polyimide flex PCB, 2.8-3.0mm encapsulated node profile, detachable battery interface, washable wearable integration

    Compression sleeve wearable node with detachable battery and sensor contact interfaces

    Pricing & Availability

    Distributor

    Qty 1

    Arrow

    $24.88–$28.50

    Digi-Key

    $15.64–$16.22

    LCSC

    $52.96

    Mouser

    $37.49

    TME

    $7.48

    Verical

    $9.97–$21.56

    Controls