Compact Stacked PCB Design for ESP32 Smart Switch (Schematics Provided)
Budget: ₹1,500 – ₹12,500 INR
I am looking for an experienced PCB designer to create a production-ready, compact PCB layout for a 4-channel ESP32-based smart switch board.
To achieve a compact form factor and ensure safety, the design must utilize a 2-board stacked architecture. One board will handle the High Voltage (AC power and relays), and the other will handle the Low Voltage (ESP32 and touch controls). The two boards will connect vertically using exposed male/female header pins.
Note: The schematics for both boards are already designed. Your task is to do the component placement, routing, and generate the final manufacturing files.
Hardware Architecture & Components:
The system is divided into two separate PCBs.
PCB 1: Power & Switching Board (High Voltage)
Power Supply: HLK-5M05 (AC to DC 5V Step-down module)
Protection: MOV-07D471K (Varistor)
Switching: 4x HK4100F-DC5V-SHG Relays
Relay Drivers: AO3400 (C2848737) MOSFETs setup for the 4 relays
Terminals: WJ500V-5.08-2P-14-00A Screw Terminals
PCB 2: Logic & Control Board (Low Voltage)
Microcontroller: ESP32-WROOM-32D
Power Regulation: AP2112K-3.3TRG1 (3.3V LDO)
IO Expansion/Control: 74HC595 (Shift Register)
Protection: TPSP0402B-ELC-01ETG (TVS Diode)
User Interface: 4x Custom capacitive touch pads (10x10mm physical dimensions on the PCB)
Key Design Requirements:
Form Factor: The layout must be highly compact to fit inside a standard wall switch enclosure (exact dimensions will be provided upon hiring).
Board Interconnect: Precise alignment of the header pins on both PCBs so they snap together seamlessly.
Isolation & Safety: Strict adherence to creepage and clearance rules on PCB 1 to safely isolate the AC mains from the 5V/3.3V DC lines.
Touch Pad Design: The 10x10mm touch pads on PCB 2 must be routed properly with minimal parasitic capacitance for reliable ESP32 touch sensing.
What I Will Provide:
Completed schematics for both PCB 1 and PCB 2.
Target physical dimensions/constraints for the final boards.
Deliverables Required:
Source Files: Original PCB layout files (preferably EasyEDA, or standard formats like KiCad/Altium).
Manufacturing Files: Order-ready Gerber files and NC Drill files.
Assembly Files: Pick and Place (CPL) file.
BOM: Consolidated Bill of Materials with exact part numbers (LCSC/Digikey/Mouser) ready for automated assembly (PCBA).
To achieve a compact form factor and ensure safety, the design must utilize a 2-board stacked architecture. One board will handle the High Voltage (AC power and relays), and the other will handle the Low Voltage (ESP32 and touch controls). The two boards will connect vertically using exposed male/female header pins.
Note: The schematics for both boards are already designed. Your task is to do the component placement, routing, and generate the final manufacturing files.
Hardware Architecture & Components:
The system is divided into two separate PCBs.
PCB 1: Power & Switching Board (High Voltage)
Power Supply: HLK-5M05 (AC to DC 5V Step-down module)
Protection: MOV-07D471K (Varistor)
Switching: 4x HK4100F-DC5V-SHG Relays
Relay Drivers: AO3400 (C2848737) MOSFETs setup for the 4 relays
Terminals: WJ500V-5.08-2P-14-00A Screw Terminals
PCB 2: Logic & Control Board (Low Voltage)
Microcontroller: ESP32-WROOM-32D
Power Regulation: AP2112K-3.3TRG1 (3.3V LDO)
IO Expansion/Control: 74HC595 (Shift Register)
Protection: TPSP0402B-ELC-01ETG (TVS Diode)
User Interface: 4x Custom capacitive touch pads (10x10mm physical dimensions on the PCB)
Key Design Requirements:
Form Factor: The layout must be highly compact to fit inside a standard wall switch enclosure (exact dimensions will be provided upon hiring).
Board Interconnect: Precise alignment of the header pins on both PCBs so they snap together seamlessly.
Isolation & Safety: Strict adherence to creepage and clearance rules on PCB 1 to safely isolate the AC mains from the 5V/3.3V DC lines.
Touch Pad Design: The 10x10mm touch pads on PCB 2 must be routed properly with minimal parasitic capacitance for reliable ESP32 touch sensing.
What I Will Provide:
Completed schematics for both PCB 1 and PCB 2.
Target physical dimensions/constraints for the final boards.
Deliverables Required:
Source Files: Original PCB layout files (preferably EasyEDA, or standard formats like KiCad/Altium).
Manufacturing Files: Order-ready Gerber files and NC Drill files.
Assembly Files: Pick and Place (CPL) file.
BOM: Consolidated Bill of Materials with exact part numbers (LCSC/Digikey/Mouser) ready for automated assembly (PCBA).
Related categories:
Electronics
Electrical Engineering
PCB Layout
Circuit Design
Embedded Systems
Prototyping