Schematic for ESP32 RC Car PCB and schema final: Template for...

Test Plan Development for PCB Project

1:51

Advanced Reasoning

Project

Trace

Below is a structured test plan to help ensure the final design meets its performance, reliability, and safety requirements. Modify and extend these items to match your organization’s standards and the specific goals of this project.

1. Introduction

This test plan covers the validation of both the functional and non-functional aspects of the project. It ensures that the final combination of hardware (PCB, onboard components, enclosures, modules) meets the design specifications such as electrical performance, thermal stability, mechanical robustness, and environmental resilience.

1.1 Project Overview

Project Name: ESP32 RC Car PCB and schema
Primary Functions:
- Control of motors, sensors, and other accessories via ESP32 module
- Onboard power regulation (+5V, +3.3V rails)
- Connectivity via ESP32 (Bluetooth, Wi-Fi)

1.2 Key Stakeholders

Design Engineering Team: Oversees board design, layout, and integration.
Test/Validation Team: Conducts test procedures and compiles results.
Project Management: Ensures timeline, budget, and readiness for manufacturing.

2. Scope

In-Scope Testing
- Electrical verification (power rails, sensors, motor drivers, I/O lines)
- Thermal analysis for power components, motor drivers, and regulators
- Mechanical and fit checks (alignments, mounting, and mechanical tolerances)
- Environmental reliability (temperature range, vibration, moisture/humidity, etc.)
- Communication links and interface testing (Wi-Fi, Bluetooth, sensor signals)
Out-of-Scope Testing
- Final overall system integration testing with remote control or software apps (beyond ensuring the PCB-level communication is functional).
- Certification testing for regulatory standards (FCC, CE, etc.) unless specified later.

3. Objectives

Validate Functional Requirements:
- Confirm each power rail has correct voltage under load.
- Ensure motor driver signals and sensor interfaces function reliably.
- Confirm correct operation of the ESP32 module for communication and control.
Validate Non-Functional Requirements:
- Assess thermal dissipation capacity under typical and extreme loads.
- Check mechanical integrity of connectors, mounting holes, and standoffs.
- Validate reliability under environmental stress (temperature/humidity).
Mitigate Risks:
- Identify failure modes and ensure they are mitigated (e.g., over-voltage on motors, improper sensor readings).
- Provide data to refine performance margins and design improvements.

4. Requirements to Validate

Below is a concise list of key requirements to be tested:

Electrical
- Supply Voltage Stability: Must remain within ±5% of nominal for 5V and 3.3V rails under maximum load.
- Motor Driver Performance: L293D driver should handle specified DC motor current without thermal shutdown.
- Sensor I/O: Sensors (HC-SR04, IR sensors) must communicate reliably.
- Communication: Wi-Fi and BLE on ESP32 must operate as expected.
Thermal
- Regulator Heat Dissipation: Linear regulators (LD1117V33, L7805CV) must keep junction temperature below specified max.
- Motor Driver Thermal Load: L293D should not exceed recommended temperature at continuous motor current.
Mechanical
- Connector Alignment: All connectors, pin headers, and sockets must align with appropriate mechanical references.
- Mounting Holes: Standoffs and mounting points must align with enclosure or chassis.
Environmental
- Temperature Range: Board must operate within expected ambient (e.g., -10°C to +60°C).
- Humidity and Moisture: No shorting or corrosion under typical humidity levels.
Interfaces
- Bluetooth: Must pair with standard devices when tested.
- Wi-Fi: Must connect to a standard 2.4 GHz network and maintain stable connectivity.
- Sensor Data: Must be read consistently over I2C/UART lines and match expected sensor specifications.

5. Test Categories & Cases 5.1 Electrical Testing

Objective: Validate power distribution, voltage levels, signal integrity, and load-handling performance.

Power-Up Test
- Procedure: Apply power from a regulated bench supply at 5V. Check 5V and 3.3V lines with no load.
- Expected Outcome: 5V rail at 5.0 ± 0.25V; 3.3V rail at 3.3 ± 0.1V.
- Pass/Fail Criteria: Voltages within specified range; stable with minimal ripple.
Full Load Test
- Procedure: Simulate maximum motor usage and sensor activation. Measure regulator output voltages and current draw.
- Expected Outcome: All supply lines remain within tolerance. Regulators do not exceed thermally-safe operating points.
- Pass/Fail Criteria: Voltage rails do not drop below tolerance; no over-current or thermal shutdown.
Signal Integrity
- Procedure: Check motor driver input signals, sensor signals with an oscilloscope.
- Expected Outcome: Clean transitions with minimal noise/ringing.
- Pass/Fail Criteria: Signal edges stable; no unexpected jitter or noise that breaks the sensor or driver logic.

5.2 Thermal Testing

Objective: Verify that onboard components (voltage regulators, MCU, motor driver) remain within safe temperature limits.

Operating Temperature
- Procedure: Operate the board at 25°C ambient for an extended period (e.g., 2 hours) with typical loads. Measure component temperatures.
- Expected Outcome: Regulator packages remain below manufacturer’s recommended junction temperature (e.g., <125°C).
- Pass/Fail Criteria: No signs of thermal throttling or overheating.
Thermal Stress under Max Load
- Procedure: Drive motors at high duty cycle for a prolonged period. Record surface temperature on L293D, regulators, and high-current traces.
- Expected Outcome: Temperature stabilizes within manufacturer limits.
- Pass/Fail Criteria: Junction temperature at or below maximum rating.

5.3 Mechanical Testing

Objective: Confirm the mechanical robustness of the PCB, connectors, and mounting points.

Connector Fit Check
- Procedure: Insert all pin headers/sockets, sensors, and modules.
- Expected Outcome: Components align properly without bending pins; board holes match mechanical references.
- Pass/Fail Criteria: Easy insertion and secure fit. No pin misalignment or mechanical strain.
Mounting & Standoff
- Procedure: Attach standoffs in designated mounting holes. Ensure clearance with chassis or enclosure.
- Expected Outcome: Board sits flat; holes align with mating enclosure.
- Pass/Fail Criteria: No mechanical interference or warped placement.
Light Vibration Check (Optional)
- Procedure: Vibrate assembly at low amplitude and frequency typical for an RC environment.
- Expected Outcome: No loosening of bolts, no cracked solder joints.
- Pass/Fail Criteria: Connectors remain seated; no visible fractures.

5.4 Environmental Testing

Objective: Verify operation over relevant temperature, humidity, and environmental stress conditions.

Extended Temperature Range
- Procedure: Place board in a temperature chamber cycling between -10°C and +60°C while powered (if those are target extremes).
- Expected Outcome: All essential functions remain operational.
- Pass/Fail Criteria: No unexpected resets or performance degradation beyond tolerance.
Humidity/Ingress
- Procedure: Expose to 80–90% humidity environment for a short cycle.
- Expected Outcome: No condensation-related shorts or corrosion.
- Pass/Fail Criteria: Board continues normal function.

5.5 Communication & Interface Testing

Objective: Validate the ESP32’s Wi-Fi, Bluetooth, sensor interrogation, and any other comm lines.

Wi-Fi Connectivity
- Procedure: Connect board to a known AP, measure throughput or ping stability.
- Expected Outcome: Reliable connection within standard ESP32 performance.
- Pass/Fail Criteria: Minimal packet loss, stable data link.
Bluetooth Pairing
- Procedure: Attempt pairing with a test device (e.g., phone or BLE-enabled PC).
- Expected Outcome: Successful pairing and data exchange.
- Pass/Fail Criteria: Stable throughput or stable link over typical distances.
Sensor & Actuator Interface
- Procedure: Trigger ultrasonic sensor, read IR sensor signals, observe motor driver commands.
- Expected Outcome: Data read consistently; motors respond to control signals.
- Pass/Fail Criteria: Observed reaction times match the design expectation.

6. Test Environment & Setup

Power Supplies: Bench power supply (adjustable 0-12 V, 5 A).
Measurement Tools: Multimeter, oscilloscope, thermal camera (or IR thermometer), logging software for sensor data.
Environmental Chamber (if available): For temperature/humidity cycling.
Motor Load: Representative or actual motors, possibly with a mechanical fixture to simulate load torque.
Reference Board/Fixture: A known functional board or test jig for comparing signals/sensor data.

7. Automation Strategies

Power & Voltage Logging
- Automated logging of multiple rail voltages using DAQ modules, especially under dynamic loads.
Sensor Data Capture
- Scripts that poll the ESP32 via serial or Wi-Fi to confirm sensor readings in real-time.
Thermal Soak
- Automated data capture from thermocouples or thermal sensors at intervals.
Connectivity & Communication
- Automated scripts that repeatedly connect/disconnect Wi-Fi or BLE to gauge reliability.

8. Edge Cases

Power Brownout: Rapidly switch input supply from 5V to lower, to simulate battery depletion or brownout.
Thermal Overload: For a short period, exceed typical motor current to see if the driver or regulators shut down gracefully.
Extreme Low Temperature: If relevant for the usage scenario, test just below or near the lower limit (e.g., -10°C).
High Vibration: If the RC environment is subject to shocks or vibrations, quickly check for solder joint or connector loosening.

9. Potential Risks & Mitigations

Risk: Overheating of regulators or motor driver.
- Mitigation: Adequate heatsinking or forced air cooling if necessary.
Risk: Sensor malfunctions in high humidity or temperature.
- Mitigation: Include conformal coating or protective enclosures if needed.
Risk: Loose mechanical connections under vibration.
- Mitigation: Lock washers, threadlock on standoffs, robust soldering.

10. Reporting & Documentation

Test Log: Maintain a spreadsheet or database tracking each test case, steps, results, and pass/fail status.
Anomaly Reports: Document unexpected behaviors or failures; track corrective actions.
Summary Report: Conclude with a final document stating overall pass/fail, recommended design changes, and re-tests needed after modifications.

11. Recommendations for Improving Coverage & Reliability

Continuous Integration for Firmware: If the ESP32 firmware is part of the design, integrate basic self-tests (checking sensor readouts, memory usage) into the firmware.
Automated Re-Testing: Rerun the test suite (voltage logging, sensor checks) after each significant PCB or firmware revision.
Extended Environmental Testing: If the product sees wide temperature swings or moisture, consider longer soak tests or real-world field tests.
Early Runner Boards: Build a small pilot batch to catch potential manufacturing issues and refine test procedures.

12. Pass/Fail Criteria Summary

Functional: All power rails within ±5% tolerance, stable communication, sensor signals valid.
Thermal: Regulator and driver temperatures within datasheet operating limits.
Mechanical: No mechanical or solder-joint failures; connectors robust.
Environmental: Board operates consistently through temperature/humidity cycles.
Communication & Interface: ESP32 connectivity stable (Wi-Fi/BLE); sensor interfaces accurate.

By following the above plan and adjusting each step to the exact requirements (e.g., test duration, pass/fail margins, acceptance conditions), the test team can confidently certify the performance and reliability of the final design before moving to production.

279 days

Ready.

SCL

IO19

SCL

IO18

IO23

IO14

SDA

IO33

IO26(TRIG)

IO13

IO25(ECHO)

IO15

SDA

IO27

IO4(P.W.M)

IO32

+3.3V

Resistance

100 Ω

BZ1

+5V

+3.3V

R11

Resistance

470 Ω

Capacitance

10u F

Capacitance

10u F

LM35

+5V

LED3

+5V

+3.3V

LM35

Resistance

10k Ω

J13

SW5

OLED

GND

LCD (I2C)

GND

J10

Servo

+5V

Reviews

Design Rule Checks

Overlapping Copper • 85

Des	Net	Des	Net
Trace 888c	GND	Trace d30d	Net 2
Trace 5542	GND	C3:+	Net 5
Trace 5542	GND	Trace 9fbe	Net 5
Trace 8082	GND	R9:P1	Net 31
Trace ae6f	GND	R9:P1	Net 31
Trace e778	GND	+5V:Pin_14	Net 2
U4:ADJ/GND	GND	Trace fe13	Net 5
Trace 294d	Net 1	Trace 3af6	Net 17
Trace 294d	Net 1	Trace 6670	Net 23
C4:+	Net 2	Trace fead	Net 5
Trace 6b9a	Net 2	Trace e778	GND
Trace 60cb	Net 5	U4:ADJ/GND	GND
Trace 3323	Net 5	Trace 5542	GND
Trace b5ae	Net 5	C4:+	Net 2
Trace d050	Net 5	U4:ADJ/GND	GND
Trace 55cb	Net 6	R8:3	Net 43
Trace 55cb	Net 6	Trace 5b35	Net 43
Trace 9696	Net 6	U2:OUT2	None
Trace 3525	Net 9	Trace dd5c	GND
Trace 30f4	Net 14	Trace 8b48	Net 15
Trace 30f4	Net 14	Trace 8134	Net 30
Trace 30f4	Net 14	Trace fe83	Net 42
Trace 30f4	Net 14	Trace 7301	Net 44
Trace 30f4	Net 14	Trace 746c	Net 65
Trace 5924	Net 15	Trace 8134	Net 30
Trace 5924	Net 15	Trace fe83	Net 42
Trace 5924	Net 15	Trace 7301	Net 44
Trace 5924	Net 15	Trace 746c	Net 65
Trace 1c0a	Net 16	Trace 5758	Net 17
Trace 1c0a	Net 16	Trace eabb	Net 29
Trace 1c0a	Net 16	Trace caaa	Net 38
Trace 3af6	Net 17	Trace b4d7	Net 36
Trace 5758	Net 17	Trace 7723	Net 20
Trace 5758	Net 17	Trace f15b	Net 26
Trace 5758	Net 17	Trace 800c	Net 27
Trace 5758	Net 17	Trace b96c	Net 29
Trace 1a9e	Net 19	Trace b9ff	Net 17
Trace 1a9e	Net 19	Trace eabb	Net 29
Trace 1a9e	Net 19	Trace caaa	Net 38
Trace 0f83	Net 20	Trace 1c0a	Net 16
Trace 0f83	Net 20	Trace 1a9e	Net 19
Trace 0f83	Net 20	Trace 8b73	Net 34
Trace 5485	Net 20	Trace a8bc	Net 26
Trace 7723	Net 20	Trace bed6	Net 28
Trace 7723	Net 20	Trace e5ac	Net 38
Trace 29eb	Net 21	C1:-	GND
Trace 29eb	Net 21	Trace 5542	GND
Trace 42f0	Net 21	Trace 5542	GND
Trace 6670	Net 23	Trace b4d7	Net 36
Trace 3e4f	Net 25	Trace d5d6	Net 6
Trace 7afc	Net 25	Trace e0af	GND
Trace 50bb	Net 25	Trace d5d6	Net 6
Trace 66c5	Net 25	Trace 9696	Net 6
Trace 66c5	Net 25	U2:IN1-	Net 6
Trace 3fe1	Net 26	Trace 5485	Net 20
Trace 8b6a	Net 27	Trace caaa	Net 38
Trace 178b	Net 27	Trace 7723	Net 20
Trace 3af1	Net 29	Trace 8b6a	Net 27
Trace b96c	Net 29	Trace bed6	Net 28
Trace b96c	Net 29	Trace caaa	Net 38
Trace eabb	Net 29	Trace f15b	Net 26
Trace c678	Net 30	Trace fe83	Net 42
D7:A	Net 31	Trace f154	Net 43
R9:P1	Net 31	Trace e0af	GND
Trace 878d	Net 31	Trace f154	Net 43
Trace 1a2f	Net 33	LM35:2	None
Trace 8b73	Net 34	Trace b9ff	Net 17
Trace 8b73	Net 34	Trace eabb	Net 29
Trace 8b73	Net 34	Trace caaa	Net 38
Trace 8a63	Net 38	U1:RX0	Net 36
Trace 2508	Net 38	Trace 6670	Net 23
Trace caaa	Net 38	Trace f15b	Net 26
Trace 14f9	Net 40	Trace 15e1	Net 53
Trace 0b4b	Net 43	Trace 55cb	Net 6
Trace 0b4b	Net 43	Trace 3e4f	Net 25
Trace 0b4b	Net 43	Trace 7c85	Net 31
Trace 3e9d	Net 43	Trace 55cb	Net 6
Trace 7301	Net 44	Trace c678	Net 30
Trace f036	Net 44	Trace fe83	Net 42
Trace 15e1	Net 53	Trace 7759	Net 40
Trace 534a	Net 54	Trace ca6c	Net 40
Trace 5465	Net 65	Trace 8134	Net 30
Trace 5465	Net 65	Trace fe83	Net 42
Trace 5465	Net 65	Trace 7301	Net 44
LM35:2	None	Trace 7634	Net 33

Invalid Layer

Reports nodes that are assigned to a layer that doesn't exist in the layout stackup.

Component Overrides

Reports components that have been modified using the "!important" flag.

Airwires

Reports missing routed traces between pads in a net.

Deprecated Rules

Reports nodes that are using rules that are not supported anymore.

Layers with Multiple Fills

Reports layers that have multiple copper fills of different nets. Make sure the Connected Layers rule value of nets with fills is valid.

Floating Copper

Detect any via, trace or copper fill island that is not connected to any net.

Protected Intrusions

Reports intrusions from objects of other nets into polygons or fills that have the Protected layout rule applied.

Missing Footprints

Reports parts that have no footprint.

Manufacturing

Manufacturer Part Number • 15

	Designator	MPN
	+3.3V	None
	+5V	None
	D8	None
	GND	None
	GND	None
	IR	None
	J2	None
	J5	None
	J10	None
	J13	None
	LCD (I2C)	None
	LM35	None
	OLED	None
	Servo	None
	SW5	None

Parts Available

Beta

Checks that all parts have a part number and are available from distributors.

System Checks

Auto-Layout

Beta

Reports issues with Auto-Layout if Flux cannot route something or must ignore a configuration.

Passive Components

Resistor Power Rating

Beta

Checks that the power traveling across a given resistor is under its rating with 50% headroom.

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Pull Up/Pull Down Presence

Beta

Checks that IC pins that require pull up or pull down resistors have them.

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Capacitor Voltage Rating

Beta

Checks that capacitors have appropriate voltage ratings to prevent overheating and ensure reliable circuit operation.

Ground
A common return path for electric current. Commonly known as ground.
jharwinbarrozo
20.5M
Net Portal
Wirelessly connects nets on schematic. Used to organize schematics and separate functional blocks. To wirelessly connect net portals, give them same designator. #portal
jharwinbarrozo
43.0M
Power Net Portal
Wirelessly connects power nets on schematic. Identical to the net portal, but with a power symbol. Used to organize schematics and separate functional blocks. To wirelessly connect power net portals, give them the same designator. #portal #power
jharwinbarrozo
11.4M
Generic Resistor
A generic fixed resistor for rapid developing circuit topology. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard resistor values: 1.0Ω 10Ω 100Ω 1.0kΩ 10kΩ 100kΩ 1.0MΩ 1.1Ω 11Ω 110Ω 1.1kΩ 11kΩ 110kΩ 1.1MΩ 1.2Ω 12Ω 120Ω 1.2kΩ 12kΩ 120kΩ 1.2MΩ 1.3Ω 13Ω 130Ω 1.3kΩ 13kΩ 130kΩ 1.3MΩ 1.5Ω 15Ω 150Ω 1.5kΩ 15kΩ 150kΩ 1.5MΩ 1.6Ω 16Ω 160Ω 1.6kΩ 16kΩ 160kΩ 1.6MΩ 1.8Ω 18Ω 180Ω 1.8KΩ 18kΩ 180kΩ 1.8MΩ 2.0Ω 20Ω 200Ω 2.0kΩ 20kΩ 200kΩ 2.0MΩ 2.2Ω 22Ω 220Ω 2.2kΩ 22kΩ 220kΩ 2.2MΩ 2.4Ω 24Ω 240Ω 2.4kΩ 24kΩ 240kΩ 2.4MΩ 2.7Ω 27Ω 270Ω 2.7kΩ 27kΩ 270kΩ 2.7MΩ 3.0Ω 30Ω 300Ω 3.0KΩ 30KΩ 300KΩ 3.0MΩ 3.3Ω 33Ω 330Ω 3.3kΩ 33kΩ 330kΩ 3.3MΩ 3.6Ω 36Ω 360Ω 3.6kΩ 36kΩ 360kΩ 3.6MΩ 3.9Ω 39Ω 390Ω 3.9kΩ 39kΩ 390kΩ 3.9MΩ 4.3Ω 43Ω 430Ω 4.3kΩ 43KΩ 430KΩ 4.3MΩ 4.7Ω 47Ω 470Ω 4.7kΩ 47kΩ 470kΩ 4.7MΩ 5.1Ω 51Ω 510Ω 5.1kΩ 51kΩ 510kΩ 5.1MΩ 5.6Ω 56Ω 560Ω 5.6kΩ 56kΩ 560kΩ 5.6MΩ 6.2Ω 62Ω 620Ω 6.2kΩ 62KΩ 620KΩ 6.2MΩ 6.8Ω 68Ω 680Ω 6.8kΩ 68kΩ 680kΩ 6.8MΩ 7.5Ω 75Ω 750Ω 7.5kΩ 75kΩ 750kΩ 7.5MΩ 8.2Ω 82Ω 820Ω 8.2kΩ 82kΩ 820kΩ 8.2MΩ 9.1Ω 91Ω 910Ω 9.1kΩ 91kΩ 910kΩ 9.1MΩ #generics #CommonPartsLibrary
jharwinbarrozo
1.5M
Generic Capacitor
A generic fixed capacitor ideal for rapid circuit topology development. You can choose between polarized and non-polarized types, its symbol and the footprint will automatically adapt based on your selection. Supported options include standard SMD sizes for ceramic capacitors (e.g., 0402, 0603, 0805), SMD sizes for aluminum electrolytic capacitors, and through-hole footprints for polarized capacitors. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard capacitor values: 1.0pF 10pF 100pF 1000pF 0.01uF 0.1uF 1.0uF 10uF 100uF 1000uF 10,000uF 1.1pF 11pF 110pF 1100pF 1.2pF 12pF 120pF 1200pF 1.3pF 13pF 130pF 1300pF 1.5pF 15pF 150pF 1500pF 0.015uF 0.15uF 1.5uF 15uF 150uF 1500uF 1.6pF 16pF 160pF 1600pF 1.8pF 18pF 180pF 1800pF 2.0pF 20pF 200pF 2000pF 2.2pF 22pF 20pF 2200pF 0.022uF 0.22uF 2.2uF 22uF 220uF 2200uF 2.4pF 24pF 240pF 2400pF 2.7pF 27pF 270pF 2700pF 3.0pF 30pF 300pF 3000pF 3.3pF 33pF 330pF 3300pF 0.033uF 0.33uF 3.3uF 33uF 330uF 3300uF 3.6pF 36pF 360pF 3600pF 3.9pF 39pF 390pF 3900pF 4.3pF 43pF 430pF 4300pF 4.7pF 47pF 470pF 4700pF 0.047uF 0.47uF 4.7uF 47uF 470uF 4700uF 5.1pF 51pF 510pF 5100pF 5.6pF 56pF 560pF 5600pF 6.2pF 62pF 620pF 6200pF 6.8pF 68pF 680pF 6800pF 0.068uF 0.68uF 6.8uF 68uF 680uF 6800uF 7.5pF 75pF 750pF 7500pF 8.2pF 82pF 820pF 8200pF 9.1pF 91pF 910pF 9100pF #generics #CommonPartsLibrary
jharwinbarrozo
1.5M
Generic Inductor
A generic fixed inductor for rapid developing circuit topology. *You can now change the footprint and 3D model at the top level anytime you want. This is the power of #generics
jharwinbarrozo
15.0k
Terminal
An electrical connector acting as reusable interface to a conductor and creating a point where external circuits can be connected.
natarius
RMCF0805JT47K0
47 kOhms ±5% 0.125W, 1/8W Chip Resistor 0805 (2012 Metric) Automotive AEC-Q200 Thick Film #forLedBlink
jharwinbarrozo
1.2M
875105359001
10uF Capacitor Aluminum Polymer 20% 16V SMD 5x5.3mm #forLedBlink #commonpartslibrary #capacitor #aluminumpolymer #radialcan
jharwinbarrozo
1.2M
CTL1206FYW1T
Yellow 595nm LED Indication - Discrete 1.7V 1206 (3216 Metric) #forLedBlink
jharwinbarrozo
1.1M

Inspect

ESP32 RC Car PCB and schema final

Controls

Properties

Availability & Pricing

Distributor		Qty 1
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	Digi-Key	$27.76–$31.42
	LCSC	$19.25–$23.29
	Mouser	$30.48
	Verical	$17.88–$30.39

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