Dual-Board ESP32 Power PCB Design -- 2

I am finalising a smart-helmet cleaning kiosk and now need a proven hardware engineer to turn the control concept into a factory-ready PCB set. At the heart of the unit sits an ESP32, Wi-Fi enabled, that must simultaneously drive high-power AC loads—a 2 kW heater, a fog-steriliser and UV lamps—and several low-voltage peripherals such as fans, magnetic locks and addressable RGB strips.

Because the kiosk will ship to commercial sites, rock-solid safety is non-negotiable. The design has to provide proper isolation between the logic side and 230 V mains, robust surge protection on every incoming line, and clean step-down conversion to 12 V and 5 V rails. I am leaning toward a two-board layout: one board dedicated to the noisy, high-current power stage and a second, quieter control board that hosts the ESP32, level-shifted GPIO, MOSFET drivers and the relay/SSR interfaces.

I do not have brand loyalties for the AC-DC modules or other discrete parts, so you are free to propose components that balance cost, availability and regulatory approvals. What matters is that the finished design can be picked up by my contract manufacturer without further edits.

Deliverables I expect
• Complete schematic with all nets annotated
• Routed PCB layouts for both boards with clear creepage/clearance markings
• Manufacturing files (Gerber/ODB++, pick-and-place, drill)
• Consolidated BOM with supplier part numbers and alternates
• Brief design-for-test document outlining how to verify isolation, surge tolerance and thermal performance on the first prototypes

If you have hands-on experience releasing mixed-signal, high-voltage hardware that contains an ESP32—or similar MCU—let’s talk timelines and your preferred tool chain (Altium, KiCad, or equivalent are all acceptable).