Miniaturize ESP32 Wearable PCB
Budget: $250 – $750 USD
**Project Overview:**
I have an existing working prototype PCB based on an ESP32-S3 system that drives LED lighting (WS2812) and uses battery power (LiPo with charging and boost circuitry). The current design functions but is not optimized for size, manufacturability, or enclosure integration.
I am seeking an experienced **professional PCB design engineer (not beginner or hobbyist)** to redesign and miniaturize this system into a **production-ready, compact PCB** suitable for integration into a wearable armband enclosure.
Preference will be given to engineers or firms located in the **United States** with demonstrated experience in **consumer electronics or wearable device design**.
**Scope of Work:**
1. **PCB Miniaturization**
* Reduce the current PCB footprint to the smallest practical size
* Replace module-based components (e.g., dev boards) with integrated IC-level design where appropriate
* Optimize component placement, routing, and layer usage
* Ensure robust power delivery and signal integrity (especially for LED data lines)
2. **Schematic & Electrical Design Refinement**
* Review and improve the existing schematic
* Ensure proper integration of:
* ESP32-S3 (or equivalent)
* LiPo battery charging (TP4056 or improved solution)
* Boost converter (e.g., TPS61023 or equivalent)
* LED output (WS2812 data line reliability)
* Power switching (hardware on/off switch)
* Add any missing protection or best-practice circuitry:
* Reverse polarity protection
* Proper decoupling
* ESD/basic protection where appropriate
3. **Connector & Mechanical Integration**
* Proper placement and orientation of JST-PH connectors (battery and LED output)
* Ensure connectors are positioned correctly for **edge exit into enclosure**
* Account for cable routing and strain relief
4. **Wearable Enclosure Considerations**
* PCB layout must support integration into a **compact armband-style enclosure**
* Consider:
* Battery placement (same board or stacked/adjacent)
* Low profile (minimize height where possible)
* Clean cable exit paths
* Collaboration with me on enclosure constraints and layout preferences
5. **Manufacturability & Production Readiness**
* Design must be suitable for **volume production (DFM/DFA)**
* Proper footprints, tolerances, and spacing
* Standard components where possible (LCSC, DigiKey, etc.)
* Avoid unnecessary complexity or exotic parts
---
**Deliverables (REQUIRED):**
The final result must include a **complete, production-ready design package**, including:
* ✅ Schematic files (native design files)
* ✅ PCB layout files (native format)
* ✅ Gerber files (manufacturing-ready)
* ✅ Drill files
* ✅ Bill of Materials (BOM) with manufacturer part numbers
* ✅ Pick-and-place (centroid) files
* ✅ Assembly drawings (PDF)
* ✅ 3D model/render of PCB (for enclosure fitment)
* ✅ Documentation of key design decisions
All files must be clean, organized, and ready to send directly to a PCB manufacturer/assembler.
---
**Additional Expectations:**
* Clear communication and ability to explain design decisions
* Willingness to iterate (at least 1–2 revision cycles)
* Verification that the design is electrically sound prior to delivery
* Experience with ESP32, battery-powered devices, and LED drivers is strongly preferred
---
**To Apply:**
Please include:
* Examples of similar completed PCB designs (especially compact or wearable devices)
* Confirmation of experience with ESP32 or similar MCUs
* Your design tools (EasyEDA, Altium, KiCad, etc.)
* Estimated timeline and cost
---
**Important:**
This is not a beginner project. I am looking for a **professional-level result** that can be used for real-world production — not a partial or experimental design.
I have an existing working prototype PCB based on an ESP32-S3 system that drives LED lighting (WS2812) and uses battery power (LiPo with charging and boost circuitry). The current design functions but is not optimized for size, manufacturability, or enclosure integration.
I am seeking an experienced **professional PCB design engineer (not beginner or hobbyist)** to redesign and miniaturize this system into a **production-ready, compact PCB** suitable for integration into a wearable armband enclosure.
Preference will be given to engineers or firms located in the **United States** with demonstrated experience in **consumer electronics or wearable device design**.
**Scope of Work:**
1. **PCB Miniaturization**
* Reduce the current PCB footprint to the smallest practical size
* Replace module-based components (e.g., dev boards) with integrated IC-level design where appropriate
* Optimize component placement, routing, and layer usage
* Ensure robust power delivery and signal integrity (especially for LED data lines)
2. **Schematic & Electrical Design Refinement**
* Review and improve the existing schematic
* Ensure proper integration of:
* ESP32-S3 (or equivalent)
* LiPo battery charging (TP4056 or improved solution)
* Boost converter (e.g., TPS61023 or equivalent)
* LED output (WS2812 data line reliability)
* Power switching (hardware on/off switch)
* Add any missing protection or best-practice circuitry:
* Reverse polarity protection
* Proper decoupling
* ESD/basic protection where appropriate
3. **Connector & Mechanical Integration**
* Proper placement and orientation of JST-PH connectors (battery and LED output)
* Ensure connectors are positioned correctly for **edge exit into enclosure**
* Account for cable routing and strain relief
4. **Wearable Enclosure Considerations**
* PCB layout must support integration into a **compact armband-style enclosure**
* Consider:
* Battery placement (same board or stacked/adjacent)
* Low profile (minimize height where possible)
* Clean cable exit paths
* Collaboration with me on enclosure constraints and layout preferences
5. **Manufacturability & Production Readiness**
* Design must be suitable for **volume production (DFM/DFA)**
* Proper footprints, tolerances, and spacing
* Standard components where possible (LCSC, DigiKey, etc.)
* Avoid unnecessary complexity or exotic parts
---
**Deliverables (REQUIRED):**
The final result must include a **complete, production-ready design package**, including:
* ✅ Schematic files (native design files)
* ✅ PCB layout files (native format)
* ✅ Gerber files (manufacturing-ready)
* ✅ Drill files
* ✅ Bill of Materials (BOM) with manufacturer part numbers
* ✅ Pick-and-place (centroid) files
* ✅ Assembly drawings (PDF)
* ✅ 3D model/render of PCB (for enclosure fitment)
* ✅ Documentation of key design decisions
All files must be clean, organized, and ready to send directly to a PCB manufacturer/assembler.
---
**Additional Expectations:**
* Clear communication and ability to explain design decisions
* Willingness to iterate (at least 1–2 revision cycles)
* Verification that the design is electrically sound prior to delivery
* Experience with ESP32, battery-powered devices, and LED drivers is strongly preferred
---
**To Apply:**
Please include:
* Examples of similar completed PCB designs (especially compact or wearable devices)
* Confirmation of experience with ESP32 or similar MCUs
* Your design tools (EasyEDA, Altium, KiCad, etc.)
* Estimated timeline and cost
---
**Important:**
This is not a beginner project. I am looking for a **professional-level result** that can be used for real-world production — not a partial or experimental design.