Wearable Health Patch

Prepared the PCBWay DFM submission materials and regenerated the STEP model. I can’t submit to PCBWay directly from Flux, but these files are ready for you to upload to PCBWay’s rigid-flex/HDI quote channel for engineering feedback.
Project files:
Upload package:
Open items:
  • Final assembly is still incomplete: DRC has unresolved airwires.
  • Use these files for PCBWay engineering review only, not fabrication release.
  • After PCBWay provides the approved stackup/via table, manually finish AD5940/ADS1292 fanout, clear airwires, rerun DRC, then regenerate final exports.
I’ll inspect the current PCB state, determine whether placement, routing, or both need work, then run the appropriate auto-layout operations and verify the applied result.
Blocked: your account currently has no available ACUs, so AI inspection and auto-layout operations are unavailable.
Current known project state:
  • 6-layer rigid-flex working layout.
  • AD5940 support placement previously reorganized.
  • PCBWay HDI-oriented rules applied.
  • Last verified state had 24 unresolved airwires.
No PCB changes were made in this session. Remaining work is to inspect the latest board state, determine whether placement and/or routing is needed, run auto-layout, apply the result, and verify DRC once ACUs are available.
Check ACU balance
List airwires
Check DRC/ERC
Manual placement review

Refine this doc
Ask about this doc
Project Specification — Neura Vital Patch
Project Overview
Status: Draft biomedical-grade architecture concept.
Neura Vital Patch is a flexible/rigid-flex wearable biosensing patch inspired by the provided prototype image. The design combines BLE wireless telemetry, a single-cell LiPo power system, ECG/heart-rate sensing, PPG optical sensing, electrochemical lactate/glucose sensing, pressure/contact sensing, motion sensing, and FPC/electrode interfaces.
Intended Use
  • Intended as a biomedical-grade development architecture, not a released diagnostic design.
  • Worn on skin as a flexible patch with embedded electrodes and microfluidic/electrochemical interfaces.
  • Battery-powered during sensing. USB-C is for charging/programming and must trigger patient-signal disable/disconnect.
  • Clinical claims for diagnostic ECG, blood glucose, lactate, SpO2, or blood pressure require later safety, regulatory, and clinical validation.
What the Device Should Do
  • Acquire ECG biopotential signals for heart-rate/rhythm research.
  • Acquire optical PPG for heart-rate/contact-quality research.
  • Acquire electrochemical lactate and glucose electrode signals through AD5940-class potentiostat/electrochemical AFE circuitry.
  • Monitor contact/pressure using a 0–300 mmHg / 40 kPa digital gauge pressure sensor.
  • Track motion for artifact rejection.
  • Report data over BLE using an nRF52840 module.
  • Monitor battery state of charge and support USB-C LiPo charging.
  • Prevent patient-applied sensing from remaining active while USB is attached.
Main Features
  • BLE wireless MCU: Raytac MDBT50Q-1MV2 / nRF52840 module.
  • USB-C sink charging input.
  • BQ24074 power-path LiPo charger.
  • TPS63031 3.3 V buck-boost rail.
  • LDK130 adjustable 1.8 V rail for MAX30102 core supply.
  • ADS1292R ECG/biopotential AFE.
  • MAX30102 PPG sensor.
  • AD5940 electrochemical AFE.
  • Honeywell MPRLS0300YG00001B pressure/contact sensor.
  • KX022-1020 accelerometer.
  • MAX17048 fuel gauge.
  • FPC connectors for ECG and electrochemical electrode tails.
System Architecture

Diagram


SPI SPI I2C I2C I2C I2C USB-C charging/programming BQ24074 power-path charger Protected 1-cell LiPo SYS_RAW TPS63031 buck-boost VSYS_3V3 nRF52840 BLE module ADS1292R ECG AFE AD5940 electrochemical AFE MPRLS pressure sensor KX022 accelerometer MAX17048 fuel gauge LDK130 1.8 V LDO MAX30102 PPG core MAX30102 LED supply ECG electrodes Current limit + ESD + analog switch Microfluidic/electrochemical electrodes Current limit + ESD + analog switch USB attach detect / safety state Patient switch control
Hardware Subsystems
Power
  • USB-C sink input with CC pull-downs and VBUS ESD clamp.
  • BQ24074 charger / power-path management.
  • Protected LiPo pack required; NTC/thermal behavior must be finalized.
  • TPS63031 buck-boost generates VSYS_3V3 from LiPo/SYS input.
  • LDK130 generates VDD_1V8 for MAX30102 VDD.
Compute / Wireless
  • MDBT50Q-1MV2 nRF52840 module provides BLE telemetry, I2C/SPI master, SWD debug, USB device pins, and reset/user controls.
  • Antenna must be placed at the flex/rigid edge with module-specific copper keepout.
ECG / Heart Rate
  • ADS1292R connected over SPI.
  • ECG electrode inputs route through current-limiting resistors, ESD array, and analog switch disconnect.
  • RLD output is included but requires final patient-disconnect/fault review.
PPG / Heart Rate
  • MAX30102 on I2C with 1.8 V core and 3.3 V LED supply.
  • Requires optomechanical baffle, opaque window/adhesive stack, and pressure/motion compensation.
Electrochemical Lactate / Glucose
  • AD5940 connected over SPI.
  • Lactate and glucose electrode nets are provisionally routed through FPC connector pins and protection/switching.
  • Chemistry, reference electrode, microfluidics, and calibration are not solved by the PCB alone.
Pressure / Contact
  • Honeywell MPRLS0300YG00001B pressure sensor on I2C.
  • Use as contact/pressure signal or research pulse waveform input. Do not claim cuffless blood pressure without clinical validation.
Interfaces and Connections
  • USB-C: VBUS, GND, CC1/CC2, D+/D−.
  • Battery: 2-pin JST PH LiPo connector.
  • SWD: 10-pin 1.27 mm Cortex/SWD header.
  • FPC J3: ECG electrode tail; active pins: ECG_RA_RAW, ECG_LA_RAW, ECG_RLD_RAW.
  • FPC J4: microfluidic/electrochemical electrode tail; active pins: LAC_WE/RE/CE and GLU_WE/RE/CE.
  • I2C: PPG, pressure, accelerometer, fuel gauge.
  • SPI: ADS1292R and AD5940.
Power and Runtime Expectations
  • Initial current budget is provisional: sleep <1 mA target, active sensing tens of mA, PPG LED pulse peaks can push system peak toward ~150 mA.
  • USB input current should initially be limited around 500 mA or less.
  • Charge current should be conservative for skin-contact thermal safety, likely ~100 mA until battery capacity and thermal model are defined.
  • Runtime depends on cell capacity, BLE duty cycle, PPG LED current/duty, electrochemical sample rate, and ECG sample rate.
Power Tree and Budget

Table


RailSourceLoadsDraft Peak
USB_VBUSUSB-CBQ24074 input500 mA input limit target
BAT_PLUSLiPo packBQ24074 BAT, MAX17048 CELLpack-dependent
SYS_RAWBQ24074 OUTTPS63031 VIN/VINA~200 mA input peak estimate
VSYS_3V3TPS63031MCU, ECG, AD5940, PPG LED, pressure, accel, fuel gauge, switches~150 mA peak estimate
VDD_1V8LDK130MAX30102 VDD<10 mA typical
Manufacturing and Assembly Expectations
  • Rigid-flex or flex-with-rigid-islands architecture is strongly preferred.
  • Use components on rigid islands; keep bend zones free of components/vias.
  • 4-layer stackup is recommended for controlled return paths, RF, USB, and analog partitioning.
  • Medical-grade biocompatible adhesive/electrode/encapsulant stack is not yet specified.
Firmware-Relevant Hardware Requirements
  • SWD programming/debug through J5.
  • BLE telemetry using nRF52840.
  • Sensor buses: I2C_SCL/SDA and SPI_SCLK/MOSI/MISO.
  • Patient-switch control: PATIENT_SW_CTRL.
  • USB attach/safety state available via USB_VBUS and charger status signals.
  • Interrupts: PPG_INT_N, ECG_DRDY_N, PRESS_EOC, ACCEL_INT1, FUEL_ALRT_N.
Physical Design Expectations
  • Flexible rounded patch form matching reference image.
  • Approximate first-pass board outline: wide rounded transparent/flex patch with left/right upper microfluidic/electrode regions, central rigid electronics island, bottom electrode/contact area, and edge USB/battery/debug access.
  • Antenna on a clean outer edge, not under battery/electrodes/copper.
  • Electrochemical and ECG high-impedance traces short, guarded, and far from USB/power/RF.
Important Design Decisions
  • Use nRF52840 module rather than bare RF SoC to reduce RF certification and antenna risk.
  • Use BQ24074 power-path charger instead of charger-only MCP73831 because sensing system may need controlled SYS power and charge management.
  • Use ADS1292R over AD8232 for digital ECG acquisition.
  • Use AD5940 for flexible electrochemical research capability.
  • Treat pressure sensor as contact/pressure input, not validated blood-pressure measurement.
  • Sensing while USB is attached is a safety risk; hardware disconnect and firmware lockout are required.
Assumptions
  • Single-cell protected LiPo pack.
  • Battery-only sensing during skin contact.
  • USB-C is not connected while active patient-applied sensing is enabled.
  • Device is development/medical design-intent, not yet certified.
  • Sweat/ISF lactate and glucose chemistry will be supplied/validated separately.
Change Notes
  • Initial architecture, schematic, and layout concept created from the supplied prototype patch image.
  • Added biomedical safety constraints from independent review: patient leakage, hardware disconnect, conservative charging, regulatory documentation, and claim limitations.
  • Project Overview

  • Intended Use

  • What the Device Should Do

  • Main Features

  • System Architecture

  • Hardware Subsystems

  • Power

  • Compute / Wireless

  • ECG / Heart Rate

  • PPG / Heart Rate

  • Electrochemical Lactate / Glucose

  • Pressure / Contact

  • Interfaces and Connections

  • Power and Runtime Expectations

  • Power Tree and Budget

  • Manufacturing and Assembly Expectations

  • Firmware-Relevant Hardware Requirements

  • Physical Design Expectations

  • Important Design Decisions

  • Assumptions

  • Change Notes

Neura Vital Patch thumbnail
Schematics and PCB layout for Neura Vital Patch with parameters

Properties

Pricing & Availability

Distributor

Qty 1

Arrow

$44.98–$63.37

Digi-Key

$2.83–$2.86

HQonline

$12.82–$12.86

LCSC

$63.05–$63.14

Mouser

$72.30

TME

$17.90

Verical

$21.54–$74.87

Controls