Wearable Health Patch
Worked for 30 sec
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.
Start Auto-Layout
Thought for 13 sec
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.
Thought for 22 sec
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
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PCB Layout Concept Notes — Neura Vital Patch
Layout Created
- Custom organic flexible patch outline: approximately 85.4 mm × 46.5 mm.
- Stackup: Standard 4 Layer.
- Component placement: all 77 components placed on top layer.
- Fill ratio: ~28.3% component area; routing-aware density nominal but feasible after spacing pass.
- Block-level silkscreen annotations added for ECG electrodes, lactate/glucose microfluidics, PPG heart rate, pressure/contact, USB/charge, and BLE antenna edge.
Placement Strategy
Table
| Region | Components / Purpose |
|---|---|
| Top/edge | U1 BLE module with antenna edge orientation and keepout intent. |
| Left service edge | J1 USB-C, J2 battery connector, U2 charger, U3/U4 regulators, L3 power inductor. |
| Upper-left | J3 ECG FPC, U5 ADS1292R ECG AFE, U11 electrode switch, ECG protection/current limiting. |
| Upper-right | J4 electrochemical FPC, U7 AD5940, U12/U13 electrode switches, electrochemical protection/current limiting. |
| Lower-center | U6 MAX30102 PPG sensor region. |
| Lower-right | U8 MPRLS pressure/contact sensor. |
| Center | U9 accelerometer, bus routing corridor, support passives. |
Routing / Fabrication Notes
- Full trace routing was not requested/completed; current board has airwires by design.
- Auto-route precheck no longer flags AD5940 fine-pitch pin trace-width issues after setting narrow trace rules on relevant AD5940 nets.
- Remaining route-check warnings are same-net overlapping pads inside the USB-C connector footprint (VBUS/GND pad pairs), which the router says it will treat as single pins. Review the USB-C footprint before manufacturing.
- AD5940 WLCSP/BGA routing likely requires fine fabrication capability: 50–75 µm rules were applied on selected AD5940 nets as a routing feasibility aid; verify with the target flex/rigid-flex manufacturer.
- Use inner ground plane and dedicated return paths; avoid routing electrode traces near USB, charger, buck-boost switch nodes, or antenna keepout.
Biomedical Layout Risks
- Patient leakage/current paths require formal isolation/leakage review.
- Electrode switch implementation is provisional; hardware USB-forced disconnect should be added before a true biomedical-grade design freeze.
- High-impedance ECG/electrochemical traces should be guarded and kept short in final routing.
- PPG requires mechanical optical isolation; the PCB placement alone does not solve ambient-light leakage or contact pressure.
- Flex reliability requires rigid islands and bend-zone keepouts; this outline is a concept, not a complete bend-stack definition.
Next Layout Steps
- Finalize manufacturer constraints for flex/rigid-flex, especially AD5940 WLCSP escape routing.
- Add explicit antenna keepout copper/route exclusion region once the exact module antenna keepout dimensions are confirmed.
- Add bend-zone keepouts and rigid-island boundaries.
- Route power and critical analog nets manually before general autorouting.
- Re-run DRC/route check after routing and adjust placement if needed.
2026-07-27 Routing Verification Update
- Most nets were auto-routed, then stale/problem traces were removed; final dangling trace count is 0.
- Final DRC still reports 26 airwires, concentrated around AD5940/ADS1292 ground/reference/fine-pitch escape, GND stitching/fills, USB-C same-net pad pairs, and a few SPI/sensor nets.
- Same-net overlapping VBUS/GND pads remain in the J1 USB-C footprint precheck; the router treats them as single pins, but this must be reviewed with the flex PCB manufacturer.
- Added bottom-side R27/R28 for the USB interlock gate network to clear top-side congestion; confirm bottom-side assembly is acceptable for the patch stackup.
- Further auto-routing is not recommended without placement/rule changes; next layout action should be AD5940 support-part re-placement and manufacturer-specific fine-pitch rule setup.
2026-07-27 AD5940 Re-placement / 6-Layer Attempt
- AD5940 support placement was revised to open escape channels: C15-C19 are now bottom-side local support capacitors around U7, with R19-R24 and U12/U13 moved outward toward J4.
- The board was moved to a 6-copper-layer routing assumption. The current stackup is an electrical/routing placeholder and still needs rigid-flex manufacturer approval.
- Added advanced routing assumptions: 75 µm trace/space for dense fine-pitch escape and 0.45/0.20 mm via baseline. Microvia/via-in-pad support is still not proven in the project stackup.
- Clean reroute reduced but did not eliminate congestion. Final status: 24 airwires remain; no manufacturing export was generated.
- Next layout action should be manual AD5940/ADS1292 fanout planning, not another blind auto-route pass.
Layout Created
Placement Strategy
Routing / Fabrication Notes
Biomedical Layout Risks
Next Layout Steps
2026-07-27 Routing Verification Update
2026-07-27 AD5940 Re-placement / 6-Layer Attempt
