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Applications And Implications, Project Development

What will it do?

My final project is a contactless controllable floor lamp.

The system consists of two separate units:

  • a sender unit, which reads the user input
  • a receiver unit, which is the actual lamp

The sender uses three VL53L0X Time-of-Flight sensors to measure the distance of my hand. These values can be used to control RGB color values or other light modes. A button is used to confirm the selected value and send it to the lamp.

The communication between sender and receiver is done via BLE.

The receiver controls a WS2812B LED strip with FastLED. The LEDs are placed inside the lamp body and covered by a self-made silicone diffuser. The goal is to create a lamp that is not only functional, but also feels like an integrated product with a clear interaction concept, clean electronics, and a finished look.

Who has done what beforehand?

There are already many smart lamps that can change color and brightness. Most commercial products use apps, remote controls, voice assistants, touch surfaces, or physical buttons.

There are also many maker projects using ESP32 boards, WS2812B LEDs, Bluetooth, Wi-Fi, and simple gesture control. Time-of-Flight sensors are also often used for interactive projects.

My project builds on these known principles, but combines them into one complete system:

  • contactless control with three separate distance sensors
  • BLE communication between two physical devices
  • custom electronics and wiring
  • a self-made sender housing
  • a self-made lamp body
  • a 3D-printed sensor integration with glass covers
  • a cast silicone diffuser
  • focus on look, finish, usability, and system integration

I also use my previous FabAcademy documentation as a technical base. This includes my work from Electronics Design, Electronics Production, Input Devices, Output Devices, Networking and Communications, Interface and Application Programming, and System Integration.

From these weeks I already have tested and documented several parts of the final project:

  • PCB design and electronics production
  • VL53L0X sensor tests
  • I²C communication with multiple sensors
  • sensor addressing using XSHUT pins
  • WS2812B LED tests
  • current measurements of the LED strip
  • BLE communication tests
  • first interface and interaction concepts
  • system diagrams and integration planning

In addition to that, I use my own notes, sketches, calculations, and tests, for example the sensor spacing, sensor angle, measurement through glass, housing concepts, cable routing, battery integration, and diffuser ideas.

What sources will I use?

I will mainly use datasheets, technical documentation, my own measurements, and my previous FabAcademy documentation.

Important sources are:

  • ESP32-C6 datasheet
  • ESP32-C6 Supermini information
  • ESP32-C3 Supermini information
  • VL53L0X datasheet
  • WS2812B technical information
  • relay module information
  • LiPo battery datasheet
  • information about the charging circuit on the ESP32-C6 Supermini
  • documentation for the external battery voltage measurement
  • Arduino ESP32 documentation
  • ESP32 BLE examples and documentation
  • FastLED documentation
  • VL53L0X library documentation
  • my KiCad files, PCB layouts, measurements, and previous test code

For the mechanical part I will use my own CAD models, sketches, material tests, and experience from the FabLab machines.

What will I design?

I will design the complete system of the contactless lamp. This includes the interaction concept, electronics, software, housings, lamp body, diffuser, sensor integration, power supply, and final appearance.

Sender unit

The sender unit contains:

  • ESP32-C6 Supermini
  • three VL53L0X ToF sensors
  • button
  • LiPo battery
  • charging circuit on the C6 board
  • external voltage measurement for battery level estimation
  • internal wiring
  • sensor holder
  • glass covers in front of the sensors

The ESP32-C6 is used in the sender because it fits better with the planned battery setup. The three sensors need to be positioned accurately, so the sensor integration will be 3D printed. This part also holds the microscope slide glass covers.

The sender housing itself will be CNC milled. It should be stable, clean, serviceable, and allow access to the USB-C charging port.

Receiver / lamp unit

The receiver unit is the actual lamp. It contains:

  • ESP32-C3 Supermini
  • relay module
  • WS2812B LED strip
  • power supply
  • internal wiring
  • LED mounting
  • silicone diffuser
  • lamp body

The ESP32-C3 receives the BLE data from the sender and controls the LED strip with FastLED. The relay module is used because the LED strip can draw much more current than the microcontroller can switch directly.

The lamp body will be made from ash wood and CNC milled. It should hold the electronics, guide the cables, position the LED strip, and integrate the diffuser. The outside should look clean and intentional, not like an open prototype.

Diffuser

The diffuser will be cast from SF33 silicone. Its job is to soften the light from the WS2812B LEDs and reduce visible LED hotspots. The diffuser must fit into the lamp body and should have a clean visible surface.

Software

The sender firmware will handle:

  • sensor initialization
  • I²C communication
  • VL53L0X addressing
  • distance measurement
  • value mapping
  • button input
  • BLE transmission
  • battery voltage reading

The receiver firmware will handle:

  • BLE reception
  • data interpretation
  • LED control with FastLED
  • relay control
  • output of the selected light color or mode

What materials and components will be used?

Electronics

  • ESP32-C6 Supermini for the sender
  • ESP32-C3 Supermini for the receiver
  • 3x VL53L0X Time-of-Flight sensors
  • WS2812B LED strip
  • relay module
  • LiPo battery
  • charging electronics on the C6 board
  • external battery voltage measurement
  • button
  • wires, connectors, pin headers, resistors, and small electronic parts

Mechanical materials

  • ash wood for the lamp body and visible wooden parts
  • SF33 silicone for the diffuser
  • microscope slide glass as sensor cover
  • 3D printing material for sensor integration and internal holders
  • screws and threaded inserts
  • sanding paper, glue, and surface finish

The ash wood is used for the main visual structure of the lamp. The silicone diffuser is used for the light output. The microscope slide glass protects the ToF sensors while keeping the front surface clean.

Where will they come from?

Some materials and components will come from the FabLab stock, especially standard electronics, wires, screws, PCB material, and general workshop supplies.

Mechanical materials and consumables will partly come from a local hardware store. This includes wood-related material, screws, sanding paper, glue, and surface finish.

Specific electronic components will come from DigiKey, especially parts where reliable datasheets and technical information are important.

The SF33 silicone will come from a specialized silicone shop.

Some standard maker modules, such as development boards, sensor boards, or small electronic modules, may come from AliExpress. For these parts I need to check pinout, quality, delivery time, and electrical limits carefully.

How much will it cost?

The final cost calculation is not finished yet.

For the bill of materials I will include:

  • microcontrollers
  • sensors
  • LED strip
  • relay module
  • LiPo battery
  • charging and voltage measurement parts
  • wires and connectors
  • PCB material
  • ash wood
  • SF33 silicone
  • microscope slide glass
  • screws and threaded inserts
  • 3D printing material
  • surface finish
  • glue and consumables

What parts and systems will be made?

Mechanical parts

  • CNC milled sender housing
  • 3D printed sensor holder
  • glass cover integration for the ToF sensors
  • CNC milled lamp body
  • LED mounting
  • cable routing
  • cast silicone diffuser
  • internal mounting points
  • access points for charging and maintenance

Electronic systems

  • sender electronics with ESP32-C6, sensors, button, LiPo battery, charging, and battery voltage measurement
  • receiver electronics with ESP32-C3, relay module, LED strip, and power supply
  • wiring and power distribution
  • LED power switching through the relay

Software systems

  • sender firmware for sensor reading, button logic, battery reading, and BLE sending
  • receiver firmware for BLE receiving, FastLED output, and relay control

The important part is that these systems do not only work separately, but as one integrated final project.

What processes will be used?

The project uses several digital fabrication and development processes:

  • concept development
  • system planning
  • block diagrams
  • CAD design
  • 3D printing for the sensor integration
  • CNC milling for the sender housing and lamp body
  • mold design for the silicone diffuser
  • silicone casting with SF33
  • PCB design or carrier board design
  • soldering and wiring
  • embedded programming
  • BLE communication
  • FastLED programming
  • sensor testing
  • battery voltage measurement
  • power testing
  • mechanical assembly
  • sanding and surface finishing
  • final integration and debugging

The 3D printed parts are mainly used where accurate sensor positioning and glass integration are needed. The CNC milled wooden parts define the main structure and final appearance of the product.

What questions need to be answered?

Sensors

  • Is the calculated sensor spacing of about 115 mm still correct in the final housing?
  • Does the slight angle of the outer sensors work in practice?
  • How stable are the values during real hand movement?
  • Is filtering needed to make the interaction smoother?

Interaction

  • Does the RGB control feel intuitive?
  • How fast should the system react?
  • Does the user understand the interaction after a short explanation?

Communication

  • Is the BLE connection stable enough?
  • What happens if the connection is lost?

Electronics and power

  • Does the relay switch reliably?
  • Are there voltage drops when the LEDs turn on?
  • Does the charging circuit work reliably?
  • How accurate is the battery voltage measurement?
  • How long does the sender run on battery?

Mechanics and design

  • Do the sensors, glass covers, and housing fit together accurately?
  • Is the sender still serviceable?
  • Is the lamp body stable?
  • Is the cable routing clean?
  • Do sender and lamp visually belong together?
  • Are look and finish good enough for a final prototype?

How will it be evaluated?

The project will be evaluated by testing the complete system and the individual subsystems.

Functional test

The sender must read hand distances reliably. The button must confirm the selected value. The value must be sent via BLE, received by the lamp, and shown on the WS2812B LED strip.

Sensor test

The three sensors will be tested individually and together. I will check the measurement range, stability, reaction to hand movement, measurement through glass, and possible interference between sensors.

Communication test

The BLE connection will be tested for connection stability, delay, reconnection behavior, and reliable data transfer between sender and receiver.

Electrical test

I will check the power supply, LED current, relay behavior, battery charging, battery voltage measurement, and possible heating of wires or components.

Mechanical test

I will check the fit of the housings, sensor holder, glass covers, LED strip, diffuser, cable routing, and internal mounting points. The lamp must stand safely and the sender must be comfortable to use.

Light test

The diffuser will be evaluated by looking at the light quality. Important points are brightness, color appearance, visible LED points, hotspots, and how well the light fits into the lamp body.

Usability test

The interaction should be understandable, stable, and not frustrating. The user should be able to control the lamp after a short explanation.

Design evaluation

The final object will also be evaluated by look and finish. Sender and lamp should look like they belong together. The wood, silicone diffuser, glass covers, electronics, cables, and screws should be integrated cleanly.

The project is successful if the contactless control works, BLE communication is stable, the lamp reacts correctly, the power system is safe, the mechanical parts are clean, and the final result feels like one integrated system.