Flexible Control PCB for Wearables
Ultra-thin flexible PCB featuring ESP32-PICO and integrated Battery Management System
Overview
Revolutionary flexible circuit board designed specifically for wearable applications. This compact design integrates the powerful ESP32-PICO-D4 microcontroller with a sophisticated Battery Management System (BMS) on a single flexible substrate. The board features advanced power management, wireless connectivity, and sensor interfaces while maintaining the flexibility and comfort required for wearable devices.
Key features
- Ultra-thin flexible PCB design (0.2mm thickness) for comfort and durability
- ESP32-PICO-D4 integration providing WiFi and Bluetooth connectivity
- Advanced BMS with overcharge, over-discharge, and short-circuit protection
- Optimized power management for extended battery life (up to 48 hours)
- Multiple sensor interfaces (I2C, SPI, ADC) for various biometric sensors
- Compact form factor (45mm x 30mm) suitable for various wearable applications
From challenge to solution
Challenge
Our solution
Designing flexible circuits that maintain electrical reliability through repeated bending
Utilized specialized flexible substrate materials with controlled impedance for reliable signal integrity
Integrating complex power management within space constraints of wearable devices
Developed custom BMS circuit optimized for space efficiency and thermal performance
Achieving optimal antenna performance on flexible substrate with body proximity
Implemented advanced antenna design with ground plane optimization for body-worn scenarios
Managing thermal dissipation in thin, flexible form factor
Created strategic copper distribution and via placement for effective heat spreading
Results & impact
- Successfully integrated into 3 different wearable product prototypes
- Passed 10,000 flex cycle testing without electrical failure
- Achieved 48-hour battery life with continuous sensor monitoring
- Reduced product development time by 40% compared to rigid PCB alternatives
Specifications
- Dimensions
- 45mm x 30mm x 0.2mm
- Microcontroller
- ESP32-PICO-D4
- Battery Support
- 3.7V Li-Po, 100-500mAh
- Charging Current
- Up to 500mA
- Wireless
- WiFi 802.11 b/g/n, BLE 5.0
- Operating Temp
- -20°C to 60°C
- Bend Radius
- Minimum 5mm
Gallery
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