PCB Design Discussion


Built the complete T‑Embed CC1101 RF/IR Backpack: 41-component schematic, dual nRF24 sockets, second CC1101 socket, high-power IR TX/RX, protected power supply, 100 × 45 mm four-layer PCB, placement, routing, BOM metadata, and bring-up documentation.
Open item
  • One false GND airwire remains on an inaccessible generated stitching via; all functional nets are connected, dangling traces are 0, and ERC power errors are 0.
  • Direct GPIO stacking, ESP32 U.FL, and carrier SMA were omitted because the real T‑Embed exposes only GPIO8, GPIO18, GPIO43, GPIO44, 3V3, and GND. The carrier therefore uses I²C bridge/expander ICs and avoids invalid parallel RF connections.
Project files
Scrap the carrier board. Design a standalone PCB from scratch with the ESP32-S3-WROOM-1U module directly on the board. Use all available GPIOs directly — no I2C expanders needed. This gives us full control over pin assignments and avoids the T-Embed's pin limitations.
Use the pin mappings from the HIZMOS project which already proved this works:
  • Full SPI bus for CC1101 + nRF24s
  • Direct I2C for display + PN532
  • Direct GPIOs for buttons, IR, SD card
I accept the extra design effort. Proceed with standalone design.
I’ll replace the carrier architecture completely with a standalone ESP32‑S3‑WROOM‑1U board, reusing the specified direct GPIO mapping while rebuilding power, charging, display, NFC, storage, dual Sub‑GHz, dual nRF24, IR, controls, and RF layout from first principles.
The standalone redesign was planned, but no project mutations were completed because the account ran out of available ACUs. The existing 41-component carrier design remains unchanged.
Remaining work:
  • Remove the carrier/bridge architecture.
  • Verify ESP32-S3-WROOM-1U-N16R8 GPIO conflicts—especially GPIO35–42 used by octal memory—and finalize a direct-pin remap.
  • Rebuild the schematic, power/charging system, radios, display, NFC, SD, controls, and IR.
  • Create and route the four-layer 100 × 45 mm PCB.
  • Run ERC/DRC and update BOM, firmware, bring-up, and regulatory files.
Document architecture requirements
Identify carrier components
Validate GPIO pin map

J1
R10
Resistance
100kΩ
R3
Resistance
10kΩ
R6
Resistance
10kΩ
R7
Resistance
R1
Resistance
49.9kΩ
R2
Resistance
15.8kΩ
R11
Resistance
100kΩ
R8
Resistance
33Ω
R9
Resistance
100kΩ
R4
Resistance
10kΩ
R5
Resistance
10kΩ
F1
C14
Capacitance
22uF
C13
Capacitance
22uF
C2
Capacitance
10nF
C5
Capacitance
100nF
C3
Capacitance
22uF
C7
Capacitance
100nF
C4
Capacitance
100nF
C10
Capacitance
100nF
C1
Capacitance
4.7uF
C6
Capacitance
100nF
C8
Capacitance
100nF
C11
Capacitance
22uF
C12
Capacitance
22uF
C9
Capacitance
100nF
U2
U4
D1
U3
J5
J4
Q1
D2
J3
J2
U1
L1
Inductance
2.2uH
J7
LED1
Project Specification
Project Overview
Four-layer cabled carrier for the LILYGO T-Embed CC1101. Status: engineering prototype / constrained by host exposure.
Intended Use
Lawful RF receive/transmit experimentation, remote-control capture/replay where permitted, and IR bring-up. Intentional jamming is out of scope.
What the Device Should Do
  • Host two plug-in nRF24L01+ modules and one second plug-in CC1101 module.
  • Provide high-power IR transmit and 38 kHz IR receive.
  • Provide protected 5 V input, local 3.3 V regulation, test/expansion access, and safe boot defaults.
System Architecture
See the Block Diagram project file. Because only GPIO8, GPIO18, GPIO43, and GPIO44 are physically exposed, the carrier uses GPIO8/GPIO18 I2C with SC18IS606 I2C-to-SPI and PCA9555 GPIO expansion. The requested direct GPIO assignments are not used.
Verified Host Interface
Official repository documentation identifies only two Qwiic connectors (3V3, GND, GPIO8 SDA, GPIO18 SCL) and UART connector (3V3, GND, GPIO43 TX, GPIO44 RX). GPIO18 is already shared with onboard PN532/BQ27220/BQ25896. GPIO43/44 are shared UART and the official external-nRF example's CE/CS. No documented exposed GPIO10/11/12/13/16/17/35/36/40/41/42 connector exists.
The carrier therefore uses a manufacturable JST-SH Qwiic cable. It is not a stacking footprint. No mounting holes are copied because sourced hole coordinates were not verified.
Power
Dedicated 5 V/2 A JST-PH input; no reliance on the undocumented current capacity of host 3V3. 1.1 A hold PPTC, TVS, AOZ1280CI 1.2 A buck at 3.3 V. Host 3V3 is sense/reference only and must not be tied to carrier 3V3.
RF and Antennas
  • nRF24 modules retain their own antennas. No parallel RF connector.
  • J6 is DNP and electrically NC: use only after selecting a CC1101 module that exposes a documented 50-ohm RF pin and a matching topology. Standard 2x4 CC1101 modules normally carry their own antenna/SMA, so populating J6 without redesign is prohibited.
  • No ESP32 U.FL provision: the standard host does not expose a documented ESP32 RF feed/zero-ohm antenna-selection point. Use the official external-antenna T-Embed variant or perform a separately documented host modification.
Physical Design
100 × 45 mm maximum, 2 mm corner radius, Top signal/components, Inner1 GND, Inner2 power, Bottom signal. Radio sockets are edge-oriented with antenna keepouts; no host mechanical-mating claim is made.
Firmware-Relevant Requirements
Host communicates with SC18IS606 and PCA9555 over Qwiic I2C. Firmware must serialize access to the shared SPI bus, initialize all chip selects high, CE low, and IR TX low before enabling radio power/traffic.
Manufacturing and Assembly
JLCPCB-oriented SMD passives and real active MPNs. Plug-in radio modules and through-hole connectors are post-assembly. J6 DNP. Inspect module pin-1 orientation before insertion.
Done Criteria and Residual Limits
Schematic, four-layer board, placement, routing and checks are required. Exact host stacking/mounting geometry and direct requested GPIO mapping are intentionally omitted because they are not physically documented as exposed.
  • Project Overview

  • Intended Use

  • What the Device Should Do

  • System Architecture

  • Verified Host Interface

  • Power

  • RF and Antennas

  • Physical Design

  • Firmware-Relevant Requirements

  • Manufacturing and Assembly

  • Done Criteria and Residual Limits