🔍 What sources will you use?

I will reference:

• ESP32-S3 documentation and Arduino core libraries
• Datasheets and manuals for the fingerprint sensor, solid-state relay, and LCD module
• Fab Academy student projects, especially related to input/output devices and interface programming
• Online tutorials and GitHub repositories for biometric access and ESP32 integration
• Forums such as Stack Overflow and Reddit for troubleshooting and optimization tips
• ChatGPT Plus, which I actively use as a support tool to clarify technical doubts, explore programming alternatives, and speed up my development process.

📦 Where will they come from?

Most components were sourced from the Fab Lab’s internal inventory, including the ESP32, display, fingerprint sensor, acrylic, PLA filament, and wiring supplies. The only external purchase was the solid-state relay (40A), which was bought from a local electronics store due to the higher current requirements of the machine. To provide realistic documentation, a reference price list will be built using Amazon — a typical supplier for the Lab.

❓ What questions need to be answered?

• How can this system be scaled to manage multiple machines in the same Fab Lab?
• What is the best method to store biometric data securely and responsibly?
• Can the case effectively resist sawdust and remain functional in a wood-based environment?
• How will future upgrades (like multi-device dashboards) be integrated?

✅ What tasks have been completed?

I have already completed the design and production of the custom PCB, along with the 3D printed case. The solid-state relay has been tested and works reliably without overheating. Initial integration and system-level tests are ongoing. About half of the wiring is finished, and some sections of the firmware are developed and functional.

🛠️ What tasks remain?

I still need to complete the rest of the wiring and finalize the code logic. I have yet to integrate the LCD messaging system, buzzer logic, and LED semaphore control together into a synchronized workflow. Further testing is required once the integration is complete.

🧪 What has worked? What hasn’t?

The fingerprint sensor, emergency stop button, buzzer, and power cutoff system via solid-state relay are all functioning as expected. The ESP32-S3 microcontroller has shown stable performance, with no issues related to power delivery or core execution.

However, one challenge occurred with the fingerprint sensor: during continuous reading cycles, it tends to overheat and begin producing false positives or erratic fingerprint detections. This behavior appears to stem from sensor saturation and thermal stress.

To resolve this, the software was optimized to limit unnecessary fingerprint scans by introducing idle periods and conditional activation of the sensor. Now, the system only performs fingerprint readings when necessary, significantly reducing sensor workload and improving accuracy.

Additionally, some handmade cables initially failed under mechanical stress or disconnection events. These were redesigned and reinforced to improve reliability and durability during field use.

🤔 What questions need to be resolved?

So far, I’ve managed to resolve all major technical questions thanks to the support of my Fab Lab coordinator and ChatGPT. I currently don’t have open technical concerns, but I will remain alert during final integration.

📅 What will happen when?

Although my original timeline was delayed, I’ve created an updated plan and checklist to track progress. This allows me to better manage integration, testing, and documentation in parallel with other Fab Academy tasks.

Below, you will find a detailed list of completed tasks under the Project Workflow Overview, followed by the Functional Testing Methodology, including short video clips showing each test.

🎓 What have you learned?

I’ve learned the importance of designing for user safety, especially when dealing with dangerous tools. This mindset guided many design decisions. I also strengthened my understanding of automation and electrical protection systems. I had never worked with solid-state relays before, so I had to research and test extensively. The PCB design and fabrication process was a big milestone in the project’s success. On a personal level, I’ve improved my time management skills by handling multiple tasks at once without neglecting the Fab Academy requirements.