Created a refined rounded handheld enclosure for the controller, optimized for PETG printing on your Anycubic Kobra 3. It includes a front display bezel, four button caps, USB-C and sensor openings, PCB mounting, battery pocket/shield, and screw-secured rear lid.
Module operates at 3.3 V or 5 V; this board uses 3.3 V supply and 3.3 V logic.
Sensor Interface
Four-pin external connector: 3V3, GND, SDA, SCL.
Shared I2C bus with touch controller and fuel gauge; one pull-up pair on the controller board.
Initial external sensor current allowance: 100 mA maximum.
Battery Indication
Fuel-gauge IC reports state-of-charge to firmware for the on-screen battery icon.
Charger status output drives a physical charge LED.
Interfaces and Connections
USB-C: 5 V input plus native ESP32-S3 USB 2.0 D+/D-.
Battery: two-pin polarized connector for one protected LiPo cell.
Display: 15-pin GH1.25 interface including power, SPI, touch I2C, interrupt/reset, backlight, and microSD chip select.
Sensor: 4-pin I2C connector.
User controls: power, reset, and boot buttons.
Power and Runtime Expectations
Nominal battery: 3.7 V, 1000 mAh; design discharge range assumed 3.0-4.2 V.
Estimated active runtime is roughly 2.5-3.5 hours depending on Wi-Fi use, backlight brightness, and sensor load.
Idle timeout is firmware configurable; shutdown removes power from the ESP32 and display.
Target off-state battery drain: below 30 uA, excluding the battery pack's own protection circuit.
Power Tree and Power Budget
See the separate Power Budget project file.
3.3 V regulator design target: at least 0.8 A continuous and approximately 1 A transient capability, verified at minimum battery voltage.
Manufacturing and Assembly Expectations
Hybrid THT/SMD prototype intended to maximize hand-assembly and repairability.
Use axial through-hole resistors, radial/disc through-hole capacitors where electrically suitable, through-hole charging LED and tactile buttons, and through-hole battery/sensor connectors.
Retain SMD for the ESP32-S3 module, USB-C receptacle, charger, soft-power controller, buck-boost regulator, fuel gauge, ESD array, display connector, USB series resistors, regulator feedback resistors, switching-regulator capacitors, and mandatory high-frequency local ceramic/bulk decoupling.
Prefer common, documented components with manufacturer datasheets and verified library footprints; do not trade regulator stability, USB signal integrity, or ESP32 transient performance for a higher THT count.
Final stackup and board dimensions are deferred to layout.
Firmware-Relevant Hardware Requirements
Native USB programming/debug.
GPIO-controlled power shutdown.
Display backlight PWM/enable control.
SPI LCD and optional microSD sharing the SPI clock/data lines with separate chip selects.
I2C touch, battery gauge, and external sensor.
Touch interrupt available as a wake/activity input while powered.
Physical Design Expectations
ESP32 antenna placed at a board edge with a copper/component keepout.
USB-C, battery, display, sensor, and power-button connectors must remain enclosure-accessible.
Display module footprint and mounting geometry must be confirmed before enclosure and final PCB sizing.
Important Design Decisions
Electronics-first prototype; enclosure work is deferred.
Use an ESP32-S3 RF module.
Use 3.3 V for both display power and logic.
Use a power-path charger plus buck-boost regulator rather than powering directly from the LiPo.
Use a dedicated pushbutton power controller rather than relying only on ESP32 deep sleep.
Selected charger/power path: BQ24074RGTT, configured for approximately 500 mA charge and input current.
Selected main regulator: TPS63070RNMR with XFL4020-152MEC 1.5 uH inductor and 470 kΩ / 150 kΩ feedback divider for 3.3 V.
Selected soft-power controller: LTC2955CDDB-1#TRPBF; its active-high enable drives the TPS63070 EN pin, GPIO4 drives KILL, and GPIO5 receives the power-button interrupt.
Selected fuel gauge: MAX17048G+T10, powered directly from BAT so state of charge remains available across system shutdowns.
GPIO mapping is fixed in the Firmware Getting Started project file.
Assumptions
Battery includes a protection circuit and permits at least 500 mA charging and 1 A peak discharge.
External sensor uses 3.3 V I2C logic and draws no more than 100 mA.
The 15-pin Waveshare interface is used rather than the 18-pin 0.5 mm FPC interface.
MicroSD support is wired where practical but is not required for first firmware bring-up.
Change Notes
Initial specification created from user requirements and verified Waveshare product documentation.
Schematic implementation selected BQ24074 + LTC2955-1 + TPS63070 power architecture, MAX17048 fuel gauge, ESP32-S3-WROOM-1-N8R8, native USB protection, and the final display/sensor GPIO map.
Display connector J2 uses a real 15-position 1.25 mm library connector; its exact mechanical mating with the requested GH-family cable remains a layout-stage verification item.
Revised to a hybrid THT/SMD construction strategy: J3/J4, LED1, SW1-SW3, most resistors, and non-critical capacitors are through-hole; high-frequency and power-stage parts remain SMD.