Mechatronics Engineer Needed for Motorized LED Lamp Prototype with Stepper, Encoder, Battery, CAD + Firmware
Budget: $400 – $450 USD
Hi,
I am looking for a hardware/mechatronics engineer or small team to build a complete physical prototype.
I already have the full requirement document.
### 1. Project Goal
Design, build, test, and ship one fully functional prototype of a **motorized minimalist wall-mounted lamp** for illuminating glass artwork.
The prototype must be compact, silent, clean-looking, battery-powered, easy to mount/remove, and suitable as the first flagship version for future small-batch production.
---
### 2. Budget & Milestones
Total budget: $400
Milestone structure:
**Milestone 1: ?
**Milestone 2: ?
Estimated timeline: ?
---
### 3. Visual / Industrial Design
- Minimalist matte black appearance
- Rectangular wall box
- Slim telescopic arm
- Compact cylindrical light head
- Clean gallery-style look
- No protruding control buttons
- All motors, electronics, battery compartment, driver boards, and wiring hidden inside the wall box as much as possible
- Design must not distract from the glass artwork
---
### 4. Motion System
- Slow, ultra-smooth automatic sweeping motion
- Motion should feel like a very slow windshield wiper / silent gallery kinetic object
- Use **stepper motor + TMC2209 silent stepper driver**
- Motor and drive system hidden inside the rectangular enclosure
- Continuous smooth sweep while active
- No jerky startup movement
- Motion range calculated from manually set arm position using encoder feedback
---
### 5. Smart Angle Detection
- Integrate **AS5600 absolute magnetic encoder**
- User can manually rotate the arm while the lamp is OFF / asleep
- When powered ON, the system reads the current arm angle
- Firmware calculates a mirrored sweep range around **90° center**
- Example behavior:
- If arm starts at **160°**, sweep range becomes **160° to 20°**
- If arm starts at **95°**, sweep range becomes **95° to 85°**
- Startup must be smooth and must not snap suddenly
---
### 6. Telescopic Arm
- Adjustable telescopic mechanism required
- Allows user to set the reach of the lamp head
- Must remain compact, rigid, and minimalist
- Must avoid wobble during sweeping motion
---
### 7. Lamp Head Swivel / Ball Joint
- Add robust **multi-directional swivel or ball joint** at the end of the telescopic arm
- User must be able to manually adjust the beam angle:
- downward
- sideways
- backward toward the artwork / wall
- Upward adjustment is not required
- Joint must hold position firmly and not drift during sweep motion
- Design must remain compact and visually clean
---
### 8. Light System
- Warm-white focused LED spot
- Preferably high-CRI LED
- Narrow beam using **TIR lens**
- Beam should highlight glass cracks clearly
- Compact cylindrical lamp head
- Safe heat management inside the lamp head
- LED behavior depends on selected operating mode
---
### 9. Power System
- Internal compartment for **2 x 18650 Li-ion cells**
- Prototype will be shipped **without batteries**
- Client will source 18650 cells locally in Germany
- Integrated **USB-C charging circuit**
- USB-C port must be placed on the **bottom-back** of the wall box
- USB-C port must be angled parallel to the wall
- Lamp should be chargeable while mounted and in operation
- Batteries should be rechargeable inside the lamp
- Charging port should stay visually discreet
- Battery safety, charging, and power management must be considered in electronics/PCB design
---
### 10. PIR Motion Sensor + Auto Timer
- Integrate compact **PIR motion sensor**
- PIR sensor placed on the **bottom** of the enclosure
- Sensor should be hidden as much as possible
- Preferred style: tiny slit or flush dark plastic window
- Detection range target: approximately **2-3 meters**
- Default inactivity timer: **5 minutes**
- Timer should be adjustable/configurable in firmware
In AUTO PIR mode:
- PIR detects viewer
- MCU wakes up
- LED turns on
- Sweep motion starts
- After 5 minutes of inactivity, LED and motor stop
- System enters low-power sleep mode
---
### 11. Invisible Capacitive Touch Control
Use an invisible capacitive touch area on the enclosure.
No protruding control buttons.
Touch loop behavior:
**Touch 1: ON - Continuous Sweep Mode**
- LED on
- Motor active
- Continuous sweep
- PIR and timer bypassed
**Touch 2: ON - Auto PIR Mode**
- PIR mode active
- LED and motor wake on motion
- Sleeps after 5 minutes of inactivity
**Touch 3: ON - Static Spotlight Mode**
- LED stays on
- Motor stops
- Arm remains completely still at current position
**Touch 4: OFF / Deep Sleep**
- System enters deep sleep / ultra-low-power state
Technical note:
- Because capacitive touch must remain detectable, OFF means ultra-low-power deep sleep, not necessarily a full mechanical power disconnect.
---
### 12. Mounting System
Use simplified double **U-hook gravity mount**.
Frame side:
- Two small inverted U-shaped metal brackets
- Approx. **3 cm wide**
- Mounted on top of the wooden art frame
- Open side faces downward and slightly forward
- One bracket on the left and one on the right side to prevent wobble/rotation
Lamp side:
- Matching upright U-shaped brackets on the bottom/back of lamp enclosure
- Brackets face upward
Mounting behavior:
- Lamp slides horizontally from front to back into the frame brackets
- Forward weight of telescopic arm creates torque and self-locks the lamp by gravity
- Lamp should not tip forward or slide out during sweeping
- To remove, user lifts the arm slightly to release torque and pulls the lamp forward
- Tool-free attachment and detachment
---
### 13. Milestone 1 Deliverables - CAD Design & Electronics Freeze
- Final mechanical architecture
- Full 3D CAD models
- Rectangular enclosure design
- Telescopic arm design
- Lamp head ball joint / swivel design
- Double U-hook gravity mount design
- Motor + encoder packaging
- Stepper + TMC2209 layout
- AS5600 encoder layout
- PIR sensor placement
- Capacitive touch control placement
- USB-C bottom-back angled port placement
- 2 x 18650 battery compartment layout
- Electronics planning
- PCB schematics
- BOM
- Firmware logic plan
- Updated small-batch cost estimate
---
### 14. Milestone 2 Deliverables - Fabrication, Assembly, Testing & Shipping
- Source remaining components
- Fabricate enclosure
- Fabricate mounting brackets
- Fabricate telescopic arm
- Assemble ball joint / swivel mechanism
- Matte black finishing
- Electronics assembly
- PCB / wiring integration
- Firmware implementation
- Silent motion tuning
- AS5600 encoder angle testing
- PIR wake/sleep testing
- Capacitive touch mode testing
- USB-C charging validation
- Battery compartment validation
- LED beam testing
- Heat check
- Final plug-and-play prototype assembly
- Protective packaging
I need someone who can deliver both design and physical prototype support.
Please apply only if you have built real kinetic/motorized hardware products before.
I am looking for a hardware/mechatronics engineer or small team to build a complete physical prototype.
I already have the full requirement document.
### 1. Project Goal
Design, build, test, and ship one fully functional prototype of a **motorized minimalist wall-mounted lamp** for illuminating glass artwork.
The prototype must be compact, silent, clean-looking, battery-powered, easy to mount/remove, and suitable as the first flagship version for future small-batch production.
---
### 2. Budget & Milestones
Total budget: $400
Milestone structure:
**Milestone 1: ?
**Milestone 2: ?
Estimated timeline: ?
---
### 3. Visual / Industrial Design
- Minimalist matte black appearance
- Rectangular wall box
- Slim telescopic arm
- Compact cylindrical light head
- Clean gallery-style look
- No protruding control buttons
- All motors, electronics, battery compartment, driver boards, and wiring hidden inside the wall box as much as possible
- Design must not distract from the glass artwork
---
### 4. Motion System
- Slow, ultra-smooth automatic sweeping motion
- Motion should feel like a very slow windshield wiper / silent gallery kinetic object
- Use **stepper motor + TMC2209 silent stepper driver**
- Motor and drive system hidden inside the rectangular enclosure
- Continuous smooth sweep while active
- No jerky startup movement
- Motion range calculated from manually set arm position using encoder feedback
---
### 5. Smart Angle Detection
- Integrate **AS5600 absolute magnetic encoder**
- User can manually rotate the arm while the lamp is OFF / asleep
- When powered ON, the system reads the current arm angle
- Firmware calculates a mirrored sweep range around **90° center**
- Example behavior:
- If arm starts at **160°**, sweep range becomes **160° to 20°**
- If arm starts at **95°**, sweep range becomes **95° to 85°**
- Startup must be smooth and must not snap suddenly
---
### 6. Telescopic Arm
- Adjustable telescopic mechanism required
- Allows user to set the reach of the lamp head
- Must remain compact, rigid, and minimalist
- Must avoid wobble during sweeping motion
---
### 7. Lamp Head Swivel / Ball Joint
- Add robust **multi-directional swivel or ball joint** at the end of the telescopic arm
- User must be able to manually adjust the beam angle:
- downward
- sideways
- backward toward the artwork / wall
- Upward adjustment is not required
- Joint must hold position firmly and not drift during sweep motion
- Design must remain compact and visually clean
---
### 8. Light System
- Warm-white focused LED spot
- Preferably high-CRI LED
- Narrow beam using **TIR lens**
- Beam should highlight glass cracks clearly
- Compact cylindrical lamp head
- Safe heat management inside the lamp head
- LED behavior depends on selected operating mode
---
### 9. Power System
- Internal compartment for **2 x 18650 Li-ion cells**
- Prototype will be shipped **without batteries**
- Client will source 18650 cells locally in Germany
- Integrated **USB-C charging circuit**
- USB-C port must be placed on the **bottom-back** of the wall box
- USB-C port must be angled parallel to the wall
- Lamp should be chargeable while mounted and in operation
- Batteries should be rechargeable inside the lamp
- Charging port should stay visually discreet
- Battery safety, charging, and power management must be considered in electronics/PCB design
---
### 10. PIR Motion Sensor + Auto Timer
- Integrate compact **PIR motion sensor**
- PIR sensor placed on the **bottom** of the enclosure
- Sensor should be hidden as much as possible
- Preferred style: tiny slit or flush dark plastic window
- Detection range target: approximately **2-3 meters**
- Default inactivity timer: **5 minutes**
- Timer should be adjustable/configurable in firmware
In AUTO PIR mode:
- PIR detects viewer
- MCU wakes up
- LED turns on
- Sweep motion starts
- After 5 minutes of inactivity, LED and motor stop
- System enters low-power sleep mode
---
### 11. Invisible Capacitive Touch Control
Use an invisible capacitive touch area on the enclosure.
No protruding control buttons.
Touch loop behavior:
**Touch 1: ON - Continuous Sweep Mode**
- LED on
- Motor active
- Continuous sweep
- PIR and timer bypassed
**Touch 2: ON - Auto PIR Mode**
- PIR mode active
- LED and motor wake on motion
- Sleeps after 5 minutes of inactivity
**Touch 3: ON - Static Spotlight Mode**
- LED stays on
- Motor stops
- Arm remains completely still at current position
**Touch 4: OFF / Deep Sleep**
- System enters deep sleep / ultra-low-power state
Technical note:
- Because capacitive touch must remain detectable, OFF means ultra-low-power deep sleep, not necessarily a full mechanical power disconnect.
---
### 12. Mounting System
Use simplified double **U-hook gravity mount**.
Frame side:
- Two small inverted U-shaped metal brackets
- Approx. **3 cm wide**
- Mounted on top of the wooden art frame
- Open side faces downward and slightly forward
- One bracket on the left and one on the right side to prevent wobble/rotation
Lamp side:
- Matching upright U-shaped brackets on the bottom/back of lamp enclosure
- Brackets face upward
Mounting behavior:
- Lamp slides horizontally from front to back into the frame brackets
- Forward weight of telescopic arm creates torque and self-locks the lamp by gravity
- Lamp should not tip forward or slide out during sweeping
- To remove, user lifts the arm slightly to release torque and pulls the lamp forward
- Tool-free attachment and detachment
---
### 13. Milestone 1 Deliverables - CAD Design & Electronics Freeze
- Final mechanical architecture
- Full 3D CAD models
- Rectangular enclosure design
- Telescopic arm design
- Lamp head ball joint / swivel design
- Double U-hook gravity mount design
- Motor + encoder packaging
- Stepper + TMC2209 layout
- AS5600 encoder layout
- PIR sensor placement
- Capacitive touch control placement
- USB-C bottom-back angled port placement
- 2 x 18650 battery compartment layout
- Electronics planning
- PCB schematics
- BOM
- Firmware logic plan
- Updated small-batch cost estimate
---
### 14. Milestone 2 Deliverables - Fabrication, Assembly, Testing & Shipping
- Source remaining components
- Fabricate enclosure
- Fabricate mounting brackets
- Fabricate telescopic arm
- Assemble ball joint / swivel mechanism
- Matte black finishing
- Electronics assembly
- PCB / wiring integration
- Firmware implementation
- Silent motion tuning
- AS5600 encoder angle testing
- PIR wake/sleep testing
- Capacitive touch mode testing
- USB-C charging validation
- Battery compartment validation
- LED beam testing
- Heat check
- Final plug-and-play prototype assembly
- Protective packaging
I need someone who can deliver both design and physical prototype support.
Please apply only if you have built real kinetic/motorized hardware products before.