Flight Controller Design
Worked for 1 min 31 sec
The board is not manufacturing-ready yet: there are 29 unrouted connections, generic passives without MPNs, and the routing precheck flags blocked fine-pitch/USB pins. I’m clearing stale routing, re-placing with explicit ESP32 antenna/USB/sensor constraints, then I’ll reroute.
Worked for 13 mins 54 sec
Routing precheck is now clean after correcting the USB/VBUS routing rules and USB pair classification. I’m starting full-board routing now.
Worked for 15 mins 19 sec
I made substantial progress, but I’m blocked from finishing because there are no available ACUs, so I can’t continue executing fixes right now.
What I accomplished:
- Resized the PCB to a compact 50 × 50 mm, 4-layer board.
- Re-placed all 34 components for a compact manufacturable layout:
- ESP32 at board edge with antenna facing outward.
- USB-C, ESD, charger, battery connector, LDO, IMU, flash, buttons, and LEDs grouped logically.
- Cleared stale routing and fixed the USB/VBUS routing precheck blockers.
- Ran full-board auto-routing successfully.
Remaining blockers before the PCB is manufacturing-ready:
- 35 invalid-layer Smart Via errors from the autorouter.
- 1 dangling trace warning.
- 22 generic passives missing manufacturer part numbers.
- Final DRC/manufacturing validation still needs to be re-run after those fixes.
Suggested next steps once ACUs are available:
- Fix/delete or regenerate the invalid Smart Vias.
- Delete the dangling trace.
- Assign real MPNs to the generic resistors/capacitors.
- Re-run DRC/ERC and manufacturing checks.
- Export Gerbers, BOM, and pick-and-place only after checks are clean.
Fix routing errors
Complete BOM MPNs
Run final checks
Export manufacturing files
