Final Project

Final Slide

Project Video

How I arrived at this idea

This is Krypto

1 year old Scottish Terrier diagnosed with Intervertebral Disc Disease (IVDD)

The deliberation process started from a very personal place — my own dog's diagnosis. Watching Krypto struggle with everyday movements made me ask whether fabrication could offer something that didn't yet exist commercially.

Most commercially available braces for pets are either too generic, too rigid, or don't address the specific biomechanical challenge of spinal impact during movement. That double gap — mechanical and diagnostic — became the starting point for Krypto Support.

Ideas I considered before deciding

Inspiration & References

Looking at similar projects helped me understand what was possible and where existing solutions fell short.

Project overview

Krypto Support is a support brace designed with an impact-absorbing system that helps reduce the stress generated during different movements such as walking, running, and jumping. This system reduces the overall impact received by pets with spinal compression conditions in the hip area.

Additionally, the design incorporates an IMU system to track the pet's daily movements and detect anomalies, allowing this information to be shared with a veterinarian to support better diagnosis and treatment. IMU sensor integration is documented in Week 9 → Input Devices.

Initial sketches

The sketching phase was about translating the concept into form — exploring how a brace could wrap around Krypto's body without restricting natural movement, while leaving space for the electronics module. The digital design process is documented in Week 2 → Computer Aided Design.

Scanning Krypto to build the base model

To build a brace that actually fits, I needed accurate geometry. I 3D scanned Krypto to generate a mesh of his body. The full scanning workflow is documented in Week 5 → 3D Scanning & Printing.

3D printing the reference model

With the scan processed, I printed a scaled physical model of Krypto's torso as a maquette for testing form and proportions.

Printed maquette — front

Scale model used to test brace fit and pattern proportions.

Printed maquette — side

Side view showing the hip geometry used for pad placement.

From 3D model to flat pattern with masking tape

Wrapping the 3D print in masking tape, then cutting and flattening the tape to get the base pattern pieces. This technique reveals the true 2D geometry of a 3D surface without guessing.

Wrapping the model

Masking tape applied directly over the 3D print.

Cutting the tape

Pattern pieces cut on the model, then removed and laid flat.

Flat pattern pieces

Each piece labeled and ready to import digitally.

Taking measurements from Krypto

Real measurements — chest circumference, torso length, hip width — taken directly from Krypto and compared against the tape pattern.

Measuring Krypto

Key body measurements taken with a soft measuring tape.

Digitizing patterns in Shapr3D

The flattened tape patterns were traced and redrawn in Shapr3D, where measurements were verified and curves refined.

Pattern in Shapr3D

Tape shapes traced as closed sketches with exact dimensions.

Cutting brace pieces on the laser cutter

Laser cutting fabric gives cleaner, sealed edges. Full workflow documented in Week 3 → Computer-Controlled Cutting.

Setup

Fabric pinned flat to the cutting bed.

Cutting in progress

Laser tracing the pattern outline.

Cut pieces

Clean edges, no fraying.

Designing the schematic in KiCad 9

XIAO ESP32-C6 + MPU-6050 on a 60×40mm single-layer board. Schematic defines all connections: power rails, I²C lines, TP4056 battery management, decoupling capacitors, and power switch. The full electronics design process is documented in Week 6 → Electronics Design.

Schematic

Full schematic showing all component connections.

PCB Layout

60×40mm single-layer routed board.

Milling the PCB on the xTool F1 Ultra

• 1
  Export Gerbers from KiCad
  Copper layer, board outline, drill file. DRC cleared before export.
• 2
  Convert with FlatCAM
  Isolation routing toolpaths for copper traces and cutout path for the outline.
• 3
  Set up the xTool F1 Ultra
  Copper-clad fixed with double-sided tape. Origin set to board corner.
• 4
  Mill traces & cut outline
  Isolation pass first, then board outline. Inspected with loupe.
• 5
  Inspect & clean
  Continuity checked with multimeter. Problem areas marked for rework.

Board on the xTool bed

Copper-clad fixed and origin set.

Milling in progress

Isolation pass carving copper traces.

Finished board

Cleaned PCB inspected for defects.

Soldering components

Started with smallest SMD parts (capacitors, resistors) and worked up to XIAO ESP32-C6 and MPU-6050. TP4056 module checked for damage before installation — one module found suspect and replaced. The full electronics production process is documented in Week 8 → Electronics Production.

SMD soldering

Passive components soldered first under magnification.

Fully assembled PCB

All components placed and soldered.

Programming the board in Arduino

Firmware on XIAO ESP32-C6: MPU-6050 data acquisition, complementary filter for pitch/roll, activity/rest detection, spinal angle tracking, lateral asymmetry, restlessness scoring. Hosts a Wi-Fi web app with /datos, /reset, /calibrar from LittleFS. Embedded programming foundations are documented in Week 4 → Embedded Programming. The web interface was developed in Week 14 → Interface & Application Programming.

// ── Krypto Support — Main Firmware ──────────────────────────
// XIAO ESP32-C6 + MPU-6050  |  Fab Academy 2026

#include <Wire.h>
#include <WiFi.h>
#include <WebServer.h>
#include <LittleFS.h>
#include <MPU6050.h>

const char* SSID     = "KryptoSupport";
const char* PASSWORD = "krypto2026";
MPU6050 imu;
WebServer server(80);

float ax_off=0,ay_off=0,az_off=0,gx_off=0,gy_off=0,gz_off=0;
float pitch=0,roll=0,spinalAngle=0;
bool  isActive=false;
unsigned long lastMotionTime=0;
int   postureChanges=0;

void setup(){
  Serial.begin(115200); Wire.begin(); imu.initialize(); LittleFS.begin();
  calibrate();
  WiFi.softAP(SSID,PASSWORD);
  server.on("/datos",handleDatos); server.on("/reset",handleReset);
  server.on("/calibrar",handleCalibrar); server.onNotFound(serveFile);
  server.begin();
}

void loop(){ server.handleClient(); readAndFilter(); detectActivity(); delay(20); }

void readAndFilter(){
  int16_t ax,ay,az,gx,gy,gz;
  imu.getMotion6(&ax,&ay,&az,&gx,&gy,&gz);
  float axF=ax/16384.0-ax_off, ayF=ay/16384.0-ay_off, azF=az/16384.0-az_off;
  float gxF=gx/131.0-gx_off,   gyF=gy/131.0-gy_off;
  float accelPitch=atan2(ayF,azF)*180.0/PI;
  float accelRoll =atan2(-axF,azF)*180.0/PI;
  const float dt=0.02,alpha=0.98;
  pitch=alpha*(pitch+gxF*dt)+(1-alpha)*accelPitch;
  roll =alpha*(roll +gyF*dt)+(1-alpha)*accelRoll;
  spinalAngle=abs(pitch);
}

void detectActivity(){
  bool motion=(spinalAngle>5.0||abs(roll)>5.0);
  if(motion){ if(!isActive){isActive=true;postureChanges++;} lastMotionTime=millis(); }
  else if(millis()-lastMotionTime>3000){ isActive=false; }
}

void calibrate()     { /* average 500 samples at rest */ }
void handleDatos()   { /* JSON: pitch, roll, angle, active, changes */ }
void handleReset()   { /* reset postureChanges */ }
void handleCalibrar(){ /* trigger recalibration */ }
void serveFile()     { /* serve LittleFS files */ }
          

Designing the PCB enclosure and hip supports

Electronics housing snaps onto the fabric strap, protects the PCB, and allows access to USB-C. Hip supports are anatomical pads to distribute pressure evenly.

PCB enclosure design

Press-fit lid with USB-C and switch cutouts.

Hip support pads

Anatomical geometry following Krypto's hip contour.

3D Printing: buckles, enclosure, and hip supports

Quick-Release Buckles — ABS

First designed in Week 2 → Computer-Controlled Cutting, refined for final build.

PCB Enclosure — TPU

Press-fit lid with USB-C and switch ports.

Hip Supports — TPU

Flexible pads, 95A shore hardness.

Two versions of the Krypto Support identity

Two logo variants developed at different points for the packaging and web dashboard.

Version 1 — designed in Week 14 → Interface & Application Programming

Version 2 — final version for packaging

Logo design timelapse:

Box design in Illustrator & visualization in Packdora

Designed in Illustrator, visualized in Packdora, then cut on the laser cutter. Tab-and-slot construction — no glue required.

Packdora visualization

3D preview before cutting any material.

Assembled box

Final box from the laser-cut pieces.

Laser cutting the packaging box

Vinyl logo cut & application

The final logo was cut in vinyl and applied to the assembled box.

Vinyl cut

Logo cut on the vinyl cutter and weeded.

Logo applied

Transfer tape used to place the vinyl on the box face.

Stereotomy model for product photography

Physical display model using stereotomy. Geometry prepared in Fusion 360, sliced with Slicer 360 for Fusion into stackable flat sections, assembled into a rigid sculptural form. 3D printing process and settings are documented in Week 5 → 3D Scanning & Printing.

Slicer 360 sections

Fusion model sliced into flat interlocking layers.

Assembly

Sections stacked and glued.

Finished model

Used as stand-in for product photography.

Brace fit test

First fit test on Krypto — buckles, hip pad alignment, gait check. Adjustments made to strap length and pad positioning.

First fitting

Brace placed on Krypto to verify fit and buckle alignment.

Gait check

Walking test to confirm no gait restriction.

PCB & web app testing

Board powered up with MPU-6050 connected, serial output monitored to verify calibration and filter output. Dashboard accessed from a phone over the ESP32's Wi-Fi AP, confirming real-time updates on /datos and responsive controls. Networking and communication setup is documented in Week 11 → Networks & Communications.

Web dashboard

Dashboard loaded on a phone over the ESP32's Wi-Fi AP.

Live demo

Real-time data updates and recalibration trigger tested on device.

From sensor data to veterinary report

The web app translates raw MPU-6050 readings into a structured PDF report that a veterinarian can read without interpreting sensor data. Activity level, impact events, spinal angle deviations, and postural asymmetry are converted into clinical language with actionable recommendations.

Final photos

Final product

Assembled brace with all components integrated.

On Krypto

Brace worn by Krypto during final testing session.

Packaging shot

Complete kit: brace, PCB module, packaging box.

Gallery

A full look at the project photoshoot.

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Components & materials

Everything used to build Krypto Support — electronics, hardware, and fabrication materials.

Download everything

All design files, firmware, and fabrication outputs packed in a single ZIP.