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17. Applications and Implications

Designing a Modular Hydroponic System. An Integrated Final Project for Automated Urban Plant Cultivation

What will it do?

The final project is a modular automated hydroponic system designed for home use. The system grows plants without soil, monitors nutrient levels (TDS), provides automatic watering and lighting, and transmits sensor data to the user’s smartphone via Wi-Fi. This project integrates a wide range of skills acquired during the Fab Academy, from 3D modeling and digital fabrication to electronics, embedded programming, networking, and user interface development

Who has done what beforehand?

Automated hydroponic systems are quite popular both in open-source communities and on the commercial market. Many solutions have already been implemented through educational platforms like Fab Academy, as well as in the form of ready-to-use consumer products.

Here are some projects by Fab Academy students that I found very interesting and inspiring. They helped me better understand different approaches to developing my own hydroponic system and gave me ideas for both technical implementation and design.

Fab Academy Student Projects.

Commercially Available Systems.

These commercially available systems demonstrate different approaches to home hydroponic growing, each with unique features:

  • Gardyn Home 4.0 - a smart vertical system with cameras and artificial intelligence, enabling automatic plant monitoring and care.

  • LetPot Smart Garden - a compact and budget-friendly solution that makes hydroponics accessible to more users without sacrificing functionality.

  • AeroGarden Harvest/Sprout - simple and reliable hydroponic kits popular for their ease of use and consistent results.

Studying these systems gave me valuable ideas on balancing technology, cost, and user convenience in my own project.

What will you design?

I am going to design a modular automated hydroponic system for home use with a minimal set of sensors and devices. The system will automatically maintain optimal conditions for plant growth, including timely nutrient delivery and aeration. All data can be monitored and the system adjusted as needed through a user-friendly interface. This approach allows creating a simple, reliable, and efficient solution for growing plants at home even with a limited set of equipment. Furthermore, an important aspect of my project will be a simple and aesthetic design that allows the system to seamlessly integrate into any home interior. Ultimately, I want to create an accessible, efficient, and user-friendly solution that helps people grow fresh and healthy plants year-round, even without extensive gardening experience.

What materials and components will be used?

I am developing a modular automated hydroponic system for home use, built with a minimal but functional set of components.

The system includes the following sensors.

  • a pH sensor to monitor solution acidity.

  • a TDS meter to measure the level of dissolved solids.

  • a temperature sensor.

  • a float sensor to detect water level.

For output devices, I’m using a water pump and an aerator, both controlled through transistors. The system is powered by a 12V power supply, which is stepped down to 5V using a voltage regulator to safely power the microcontroller and sensors.

Most of the structural components were 3D-printed using PET-G plastic, which is UV-resistant and well-suited for working with water.

To maintain root moisture, I decided to use compressed cellulose sponge material, which can be precisely cut to shape using a laser cutter.

This approach allows me to create a durable, affordable, and customizable system suitable for growing plants in an urban apartment setting.

Where will they come from and how much will they cost?

The majority of the electronic components, including sensors, the water pump, were ordered through the online platforms AliExpress and Wildberries, as it offers a wide range of affordable options well-suited for prototyping and DIY projects.

BOM

Components Price (USD)
ESP32C3 Seeed Studio XIAO BLE WIFI module $ 4.70
PH meter $ 13.51
TDS meter $ 2.20
Тemperature sensor DS18B20 $ 0.49
Water pump $ 0.68
Aerator $ 2.13
PVC universal tube 6 mm*5 meters (food grade hose) $ 3
16 mm button with indicator, housing mounting / Locking $ 4,66
Power connector 5.5x2.5mm socket $ 2,19
PET-G plastic 2X $ 28,76
12V 2A Universal power supply 5.5x2.5mm $ 4,65
Water reservoir(Local shop) $ 15,63
Total $ 77,8

What parts and systems will be made?

  • Main structure and modular plant units - will be fully designed and 3D printed using PET-G plastic, which is strong, water-resistant, and well-suited for functional parts.

  • Holders and mounts for sensors and tubes - also 3D printed in PET-G.

  • Laser-cut cellulose sponge inserts - used to retain moisture and support plant roots.

  • Electronic control system - includes designing a custom PCB in KiCad, milling the board, and soldering all key components: microcontroller, transistors, voltage regulator, and connectors.

  • Electronics enclosure and wiring - made from PET-G plastic to house and protect the system.

  • User interface (Blynk) - allows real-time control and monitoring from a smartphone.

What processes will be used?

  • 3D printing (FDM) - for printing the frame, holders, and containers.

  • Laser cutting - for shaping cellulose sponge pads.

  • Electronics assembly - soldering and connecting components to the board.

  • Microcontroller programming - writing code to read sensors and control the pump and aerator.

  • Mobile app integration - using the Blynk platform for visualization and remote control.

  • Testing and calibration - to ensure proper system functionality and performance.

What questions need to be answered?

  • How accurate are the sensors (pH, TDS, temperature, float) in humid and wet environments over time?
  • Do sensors require shielding or electrical isolation from pump and aerator interference?
  • How reliable is the water pump during continuous operation? Does it require regular maintenance?
  • What water level is optimal to ensure consistent moisture inside the plant modules?
  • How often should the cellulose sponge be replaced? Can it be cleaned or sterilized for reuse?
  • Is data transmission via the Blynk platform accurate and fast enough for real-time monitoring?
  • Does the enclosure require additional heat protection or ventilation?
  • Can the ergonomics of the modules be improved - is it easy to access and handle the plants?

How will it be evaluated?

  • Functionality - the system should automatically monitor pH, TDS, water temperature, and liquid level, and control water flow and aeration.

  • System integration - all sensors, actuators, and the control board should work together as a cohesive unit.

  • Digital fabrication - the use of digital fabrication tools such as 3D printing, laser cutting for sponge inserts, and PCB milling.

  • Programming - working and well-structured code that reads sensors, controls outputs, and communicates via the Blynk app.

  • Documentation - complete documentation including process description, design files, cost breakdown, testing, and results.

  • Replicability and openness - the project should be reproducible by others using shared design files and clear instructions.

  • System thinking - all components (mechanical, electronic, software, and interface) should form a complete and functioning system.

What tasks have been completed?

  • Designed and 3D printed the enclosure and plant modules

  • Designed control PCB in KiCad and milled the board

  • Assembled and soldered electronic components (sensors, transistors, voltage regulator, connectors)

  • Wrote basic code to read data from pH, TDS, temperature, and float sensors

  • Implemented control of water pump and aerator using transistors

  • Performed laser cutting of cellulose sponge inserts for moisture retention

  • Set up integration with Blynk mobile app for remote parameter monitoring

  • Conducted initial testing of component functionality and system integration

What tasks remain?

  • Conduct long-term testing to verify the reliability of sensors and actuators

  • Optimize control algorithms for more precise maintenance of water parameters and humidity

  • Develop a more user-friendly and ergonomic design of the modules for easy plant maintenance

  • Implement additional features such as automatic fertilizer dosing or lighting control

  • Improve protection of electronics against moisture and temperature fluctuations

  • Prepare detailed documentation and instructions for replicability

  • Develop notification and alert system via the mobile app

What has worked? What hasn’t?

  • The electronics, including the microcontroller and sensors (pH, TDS, temperature, and liquid level), have been successfully assembled and function correctly

  • The water pump and aerator are properly controlled via transistors and respond reliably to the microcontroller commands

  • The modules and enclosure printed from PET-G are water-resistant and UV-stable

  • Laser-cut cellulose sponge inserts accurately hold moisture and fit well in the modules

  • Remote monitoring and control via the Blynk app work, with real-time sensor data displayed

  • The main software reliably reads sensor data and controls the actuators

What questions need to be resolved?

  • How to ensure long-term stability and accuracy of sensor readings (especially pH and TDS) in a constantly wet and nutrient-rich environment?

  • How to properly calibrate and maintain sensors over time to avoid data distortion?

  • How to implement automatic adjustment of the nutrient solution composition (for example, adding water or nutrient solution) based on sensor data?

  • How to optimize the control logic for the pump, aerator, and other devices so they respond to actual readings rather than operating on a fixed schedule?

  • How to add LED lighting to support plant growth and integrate its control into the mobile application?

  • How to implement an alert or fail-safe system in case of sensor or actuator failure?

What will happen when?

Stage 1. Visual Design and Modularity

Stage 2: Electronics and Automation

What have you learned?

During the development of my hydroponic system, I gained valuable hands-on experience in several key areas. I learned how to effectively use 3D printing to create durable and water-resistant parts from PET-G plastic, suitable for the operating conditions of a hydroponic environment. I also mastered PCB design in KiCad, including milling and soldering electronic components, which allowed me to build a reliable control system. Integrating various sensors, pH, TDS, temperature, and water level, taught me how to work with different types of signals and ensure accurate data collection. Programming the microcontroller to read sensor data, process it, and control actuators such as the pump and aerator became an important learning step. In addition, I explored the possibilities of remote monitoring and control through the Blynk mobile application, which enables real-time system management. I came to understand the importance of protecting electronics from moisture and environmental factors to ensure long-term reliability. Working with laser cutting to shape cellulose sponge inserts demonstrated an effective way to maintain optimal moisture levels for plant roots. Finally, I realized that thorough testing and calibration are essential steps for stable and precise system operation.