Compact ESP32 PCB

Job ID: 40443569

Budget: ₹1,500 – ₹12,500 INR

I need a compact custom PCB designed for an embedded UAV safety subsystem. The board should integrate sensing, control, power management, battery charging, status indication, buzzer alert, and PWM-based servo actuation into a single 2-layer PCB.

The design should be based on an ESP32-WROOM module, not an ESP32 development board. The onboard sensor should be the MPU6050 IMU, as the existing firmware and ML model are built around this sensor. The board should also include a servo output for parachute deployment, a loud buzzer, a main power switch, battery input, onboard single-cell Li-ion/LiPo charging and protection, USB Type-C programming/debugging, and required LEDs.

Maximum board size: 80 mm × 80 mm. The board should be kept as compact as realistically possible while preserving reliable routing, power stability, ESP32 antenna clearance, and separation between noisy servo/power sections and the IMU.

Required functional blocks:

1. ESP32-WROOM module with required boot/reset/programming circuitry
2. MPU6050 IMU connected over I2C
3. USB Type-C programming/debug interface
4. USB-UART bridge for ESP32 flashing
5. Single-cell Li-ion/LiPo battery input
6. Onboard battery charging and protection circuit
7. Clean 3.3 V rail for ESP32 and MPU6050
8. Separate high-current servo power rail
9. PWM servo output connector
10. Loud buzzer driven safely through a transistor/MOSFET driver if needed
11. Main power switch
12. Power/status LEDs
13. Test/debug pad for timing probe

Firmware-fixed pinout:

* GPIO19 = I2C SDA for MPU6050
* GPIO22 = I2C SCL for MPU6050
* GPIO2 = status LED
* GPIO23 = buzzer output
* GPIO25 = servo PWM output
* GPIO0 = button / boot / force-arm input
* GPIO4 = probe/debug timing output
* TX0/RX0 = USB-UART programming and serial debug
* MPU6050 I2C address = 0x68

Power requirements:
The ESP32 and MPU6050 should run from a clean 3.3 V rail. The servo must not be powered from the ESP32/logic rail. It should have a separate high-current 5 V servo rail with sufficient decoupling and a large bulk capacitor near the servo connector to prevent brownouts during deployment. Logic and servo power domains should be separated carefully while maintaining a proper ground strategy.

Layout requirements:

* 2-layer PCB
* ESP32-WROOM antenna at board edge with correct copper keepout
* MPU6050 placed away from switching regulators, inductors, buzzer current paths, and servo power traces
* Servo connector and bulk capacitor placed close together
* USB-C placed at an accessible board edge
* Battery/charging/protection section placed logically near the battery input
* Wide traces for servo and battery power
* Bottom layer should be used as a strong ground reference wherever possible

Deliverables:

1. Complete schematic
2. Routed PCB layout
3. Gerber and drill files
4. BOM with part numbers and footprints
5. Pick-and-place file if assembly is planned
6. Native KiCad/EasyEDA/Altium project files

Preferred toolchain: KiCad, but EasyEDA or Altium is acceptable if the workflow is faster.

The goal is a manufacturable, reliable first integrated hardware revision, not unnecessary miniaturization. The board should pass basic DRC/DFM checks and be suitable for fabrication through JLCPCB or a similar PCB manufacturer.