Okay. I had to move R4 and J7. Sorry if that messes anything up.
Also. There are still issues. RT6 is only connected on one side. C23. RT4 C25. C14. Countless others are only wired up on one size.
Also, ESP32 devkits have a capacitor? Or resistor? That is wired in so you can flash firmware without the S1 and S2 buttons. And I'm not sure if the buttons are necessary, so I'm happy to save money if we can safely nix them.
I’ll re-check the layout after your R4/J7 move, distinguish PCB airwires from actual schematic one-sided wiring, then evaluate whether BOOT/RESET buttons can be removed in favor of ESP32-S3 native USB auto-download behavior.
Verified RT6/C25, RT4/C23, C14, and related passives are schematic-connected on both sides; the issue was PCB routing/airwires, not one-sided schematic wiring.
Removed optional S1 BOOT and S2 RESET buttons to save BOM/assembly cost.
Kept the important ESP32 support: R4 GPIO0 pull-up, R3 EN pull-up, and C11 EN reset-delay cap.
Cleaned stale routing from your R4/J7 move and re-routed.
Final checked categories are clean: no airwires, dangling traces, copper overlaps, invalid layers, or relevant ERC errors.
Open items:
If we want best serviceability, add tiny labeled test pads for GPIO0/BOOT and EN/RESET later; they are cheaper than buttons and useful for recovery.
Suggested next steps:
Visually inspect the routed PCB.
Add/verify GND pours and antenna keepout.
Run full manufacturing DRC before export.
Update firmware/bring-up docs to note USB flashing without BOOT/RESET buttons.
USB Type-C / USB-PD compliance claims, if marketed
RoHS / REACH / WEEE obligations for sale regions
Product Description
ESP32-S3 based USB-C powered controller for four 5 V / 1 W off-board heater strips. The PCB includes USB-C power/programming, USB-C PD sink controller intended for 5 V-only operation, eFuse protection, 3.3 V buck regulator, WiFi/Bluetooth module, four MOSFET heater outputs, six PCB-mounted NTC temperature sensors, OLED/Qwiic I2C connector, rotary encoder, RGB status LEDs, and UART fallback header.
Wireless Technology Summary
Table
Module
MPN
Technology
Frequency Band
TX Power
Pre-certified?
Notes
U1 ESP32-S3-WROOM-1-N4R2
ESP32-S3-WROOM-1-N4R2
WiFi 2.4 GHz, Bluetooth LE
2.4 GHz ISM
Per Espressif module datasheet/grants
Use module certification evidence
Final host still needs integration review and emissions testing
Required Documentation Checklist
Project specification — created in Flux
Power/thermal budget — created in Flux
Firmware starter — created in Flux
Board bring-up plan — created in Flux
Preliminary safety/FMEA documents — created in Flux
User manual outline — created in Flux
Draft Declaration of Conformity — included below
Final schematic PDF/export after design freeze
Final PCB layout/Gerbers after routing and DRC
Final BOM with locked MPNs, lifecycle, RoHS, and alternates
ESP32-S3-WROOM-1 module datasheet and certification grants
Antenna integration evidence and keepout compliance screenshots
Accredited EMC/RF test reports from final product
USB-C/PD compatibility and compliance test evidence, if making USB-PD claims
RF Design Notes
Use the ESP32-S3-WROOM-1 integrated PCB antenna only as specified by Espressif.
Maintain antenna keepout and board-edge placement per module datasheet.
Do not route copper, traces, ground pour, heater currents, or display/encoder cables through the antenna keepout.
Enclosure plastics, labels, metal fasteners, or nearby heater wiring must not detune the antenna without validation.
Final host product requires emissions testing even when using a pre-certified radio module.
USB-C / PD Notes
Product requirement is smooth operation from dumb 5 V USB-C adapters and PD laptop chargers.
The schematic uses STUSB4500 as a PD sink controller, but the downstream system is currently 5 V-only.
Production requirement: program and verify STUSB4500 NVM/PDOs as 5 V-only before exposing the board to PD sources.
Do not rely on a 5 V TVS to clamp a negotiated 15 V/20 V contract.
If USB-PD is marketed, maintain a cable/source compatibility matrix and test attach/detach, dead-battery behavior, VBUS discharge, and PD contract behavior.
EMC Risk Notes
Heater PWM edges and long heater leads can create conducted/radiated emissions.
Gate resistors R20-R23 help edge control, but final PWM frequency, edge rate, cable length, and enclosure/wire routing require test.
USB D+/D- must be routed as a short 90 Ω differential pair with ESD part U5 close to J1.
The buck converter U3/L1 layout is a likely emissions source; keep switching loop compact.
Draft Declaration of Conformity
We, Alcove Robotics, declare that the product ESP32 Heater Controller is intended to conform to applicable requirements for radio, EMC, safety, and restricted substances in intended sales regions, subject to final design verification and accredited testing.
Authorized signatory: ______________________
Date: ______________________
Open Items / Action Required
Lock final component MPNs for generic passives and safety-relevant parts.