Week 16
Applications and Implications

ASSIGNMENT
Plan a final project masterpiece that integrates 2D/3D design, additive and subtractive fabrication, electronics design and production, embedded microcontroller interfacing and programming, system integration and packaging.
PROJECT
Krypto Support — Wearable Activity Monitor for a Scotch Terrier with IVDD
Project Development
01. What will it do?
Krypto Support is a wearable vest for my Scotch Terrier, Krypto, who was diagnosed with Intervertebral Disc Disease (IVDD). The vest embeds an IMU sensor (MPU-6050) that continuously monitors his movement, orientation, and activity levels throughout the day.
The data is processed by a XIAO ESP32 microcontroller and transmitted via Wi-Fi to a web dashboard where I can see real-time alerts when unusual movement patterns are detected — such as a sudden loss of balance, abnormal gait, or a sharp drop in activity.
The dashboard also logs all data over time, so I can export a CSV report and share it with Krypto's veterinarian. Instead of describing symptoms from memory, the vet gets objective, timestamped data showing exactly what happened, when, and how often.
02. Who has done what beforehand?
Several related projects and products informed this design:
- 1 FitBark / PetPace — commercial pet activity trackers that clip to collars. They track general activity but don't focus on neurological conditions like IVDD, and their data is locked into proprietary apps with no CSV export.
- 2 Sports medicine IMU wearables — research projects using body-worn IMUs to detect gait abnormalities in human patients. The threshold-based alert logic is adapted from this field.
- 3 Previous Fab Academy wearable projects — several students have built pet or human wearables, helping me understand how to route electronics inside textile garments and design removable PCB pockets.
- 4 Veterinary telemedicine platforms — inspired the data export and report features, since vets increasingly work with remote monitoring data.
03. What sources will you use?
| Source | Purpose |
|---|---|
| MPU-6050 datasheet | I2C communication, register maps, calibration procedures |
| XIAO ESP32 docs (Seeed Studio) | Pinout, Wi-Fi API, power management, deep sleep modes |
| Fab Academy lecture notes | Electronics design, embedded programming, networking, system integration |
| Arduino / ESP-IDF libraries | Adafruit MPU6050 library, ESPAsyncWebServer for the dashboard |
| IVDD clinical literature | Clinically meaningful movement metrics: gait symmetry, fall detection |
| Open-source pet wearable repos | Reference implementations for IMU-based activity classification |
04. What will you design?
- 1 Fitted vest garment — custom-patterned to Krypto's measurements, with integrated wire channels and an internal electronics pocket.
- 2 Custom PCB — designed in KiCad with the XIAO ESP32 footprint, IMU connector, status LED, button, and LiPo charging circuit.
- 3 3D-printed enclosure — designed in Shapr3D to house the PCB and battery inside the vest pocket, with openings for USB charging and the IMU cable.
- 4 Web dashboard interface — HTML/CSS/JS frontend displaying real-time movement data, alert history, and a CSV export button.
- 5 Firmware — C++ code for the ESP32 that reads the IMU, applies threshold logic, and transmits data over Wi-Fi.
05. What materials and components will be used?
FABRICATED (MADE)
- Custom PCB (milled on Roland SRM-20)
- 3D-printed enclosure (PLA, on Bambu Lab P1S)
- Laser-cut vest pattern pieces
- Sewn textile vest (neoprene + mesh)
- Vinyl-cut labels and markings
- Silicone comfort pads (molding & casting)
SOURCED (BOUGHT)
- XIAO ESP32-C3 module
- MPU-6050 IMU breakout
- LiPo battery 3.7V 500mAh
- SMD components (resistors, caps, LED)
- Velcro straps, buckles, thread
- FR1 copper board
06. Where will they come from?
| Component | Source |
|---|---|
| XIAO ESP32 & MPU-6050 | Fab Lab inventory / Seeed Studio online store |
| SMD components (1206 resistors, caps, LEDs) | Fab Lab inventory |
| FR1 copper board | Fab Lab stock for PCB milling |
| PLA filament | Fab Lab 3D printer supply |
| Neoprene fabric & mesh | Local fabric store in Puebla |
| LiPo battery | MercadoLibre / Amazon México |
| Velcro, buckles, thread | Local haberdashery |
07. How much will they cost?
| Component | Source | Cost (USD) |
|---|---|---|
| XIAO ESP32-C3 | Seeed Studio | $4.99 |
| MPU-6050 breakout | Fab Lab / online | $2.50 |
| LiPo battery 500mAh | MercadoLibre | $5.00 |
| FR1 board + SMD components | Fab Lab | $3.00 |
| PLA filament (~30g) | Fab Lab | $1.00 |
| Neoprene + mesh fabric | Local store | $8.00 |
| Velcro, buckles, thread | Local store | $3.00 |
| Vinyl for labels | Fab Lab | $0.50 |
| TOTAL ESTIMATED COST | ~$28.00 | |
08. What parts and systems will be made?
Roland SRM-20
PCB + battery
assembled
on ESP32
alerts + CSV
09. What processes will be used?
| Fab Academy Skill | Process | Application |
|---|---|---|
| 2D design | Illustrator / KiCad | Vest pattern layout; PCB schematic and layout |
| 3D design | Shapr3D | Enclosure modeled parametrically to PCB dimensions |
| Subtractive fabrication | CFL-CMA 1080K | Vest pattern laser-cutting |
| Additive fabrication | Bambu Lab P1S | 3D-printed electronics enclosure in PLA |
| Electronics design | KiCad 7 | Schematic capture and PCB layout |
| Electronics production | Milling + soldering | PCB fabrication, SMD component assembly |
| Embedded programming | Arduino IDE / C++ | Firmware: IMU reading, threshold logic, Wi-Fi server |
| Networking | ESP32 C6 Wi-Fi | Local web server; browser connects over Wi-Fi |
| Molding & casting | Silicone | Comfort pads cushioning the IMU against Krypto's body |
| Textile / sewing | Neoprene | Garment assembly with wire channels and pocket |
| Vinyl cutting | Silhouette / Cricut | Labels and branding on the packaging exterior |
10. What questions need to be answered?
- ? What IMU sampling rate gives the best balance between data quality and battery life?
- ? What acceleration and gyroscope thresholds reliably distinguish a stumble from normal play?
- ? How long will the LiPo battery last in continuous monitoring vs. periodic sampling?
- ? Can the vest withstand daily wear without displacing the sensor?
- ? What is the effective Wi-Fi range from the vest to the router in a typical home?
- ? How should the data be structured for a vet — raw logs, summary statistics, or flagged events?
- ? Is the enclosure resistant enough for light rain or drool?
11. How will it be evaluated?
- ✓ Functional test — Krypto wears the vest for a full day; the dashboard receives continuous data without disconnections.
- ✓ Alert accuracy — simulate known movement patterns (rest, walk, stumble) and verify the system triggers correct alerts.
- ✓ Comfort test — observe Krypto's behavior while wearing the vest: no scratching, biting, or restricted movement.
- ✓ Battery endurance — measure hours of continuous operation before recharging (target: 8+ hours).
- ✓ Data quality — export a CSV log and verify it contains complete, well-formatted, timestamped readings with no gaps.
- ✓ Vet feedback — share a sample data export with Krypto's veterinarian and ask if the format and metrics are clinically useful.
Success criteria
The project is successful when Krypto can wear the vest comfortably for a full day, the dashboard shows real-time movement data without interruptions, alerts are triggered accurately when abnormal patterns occur, and the exported data is clear enough that a veterinarian can use it to assess IVDD progression — all built with processes and skills learned throughout Fab Academy.
Development Schedule
Task timeline
The remaining weeks are organized so that each subsystem is built, tested individually, and then brought together during the final integration phase.
| Order | Task | Deliverable |
|---|---|---|
| 1 | Finalize PCB design in KiCad; mill board | Fabricated and soldered PCB |
| 2 | 3D print enclosure; iterate fit with PCB and battery | Printed enclosure, snug fit confirmed |
| 3 | Firmware: IMU reading, threshold logic, Wi-Fi transmission | Working firmware streaming data |
| 4 | Web dashboard: real-time display, alerts, CSV export | Functional dashboard in browser |
| 5 | Cut & sew vest; integrate wire channels and pocket | Finished garment with electronics |
| 6 | Full system test on Krypto; iterate comfort and alerts | Validated wearable, 8h battery test |
| 7 | Documentation, summary slide, video clip, presentation | Final presentation materials ready |