WEEK 06 – Electronics Design

This assignment focused on understanding the complete electronics design workflow, from the initial circuit idea to a PCB layout ready for fabrication. I used KiCad as the main Electronic Design Automation software to design a custom board based on the Seeed Studio XIAO ESP32-C3.

The objective was to design a board capable of controlling two servo motors using PWM signals. This process included circuit simulation, schematic design, footprint assignment, PCB layout, routing, design rule checking, 3D inspection, and preparation of manufacturing files.

This week was important because it connected embedded programming with physical electronics design. Instead of only wiring components on a breadboard, I created a structured PCB design that could be fabricated and used as part of an embedded control system.

• ✅ Linked to the group assignment page.
• ✅ Used test equipment to observe the operation of a microcontroller circuit board.
• ✅ Documented the use of laboratory instruments.
• ✅ Designed a custom circuit board using KiCad.
• ✅ Used the XIAO ESP32-C3 as the main microcontroller.
• ✅ Simulated the system before PCB design.
• ✅ Assigned footprints and created the PCB layout.
• ✅ Routed the PCB and added a ground plane.
• ✅ Checked the design using ERC and DRC.
• ✅ Included visual evidence, problems, results, and final reflection.

The practical activity focused on learning how to inspect electronic systems using available laboratory equipment. The system under analysis was an ESP32-C3 development board powered through USB and operating with 3.3V logic levels.

Through this exercise, we observed electrical behavior, voltage measurements, and signal stability. This helped reinforce the relationship between theoretical circuit design and real embedded electronics behavior.

This type of validation is important in Fab Academy because custom electronics must be tested and documented before being integrated into a larger system or final project.

Electronics design is the process of creating a functional electronic circuit that can later be fabricated as a printed circuit board. This process usually begins with a schematic, where the electrical connections are defined, and continues with the PCB layout, where components are physically arranged on a board.

In this assignment, electronics design involved choosing the main components, defining the power and signal connections, assigning physical footprints, routing copper traces, and verifying that the board could be manufactured correctly.

KiCad is an open-source Electronic Design Automation software used to design schematics and printed circuit boards. It allows designers to create electronic diagrams, assign component footprints, route PCB traces, inspect the board in 3D, and generate manufacturing files.

I used KiCad because it provides a complete workflow for Fab Academy electronics assignments. It also allows the use of Fab Academy libraries, which include symbols and footprints commonly used in digital fabrication projects.

Before starting the PCB design process, I simulated the circuit in Wokwi. This step helped me verify the logic of the system and confirm that the two servo motors could be controlled using PWM signals from the ESP32-C3.

Simulation is useful because it reduces errors before fabrication. It allows testing the firmware, checking the pin connections, and validating the behavior of the system in a virtual environment.

After validating the circuit in Wokwi, the firmware was developed in Arduino IDE. The program controls two servo motors using PWM signals and predefined movement sequences.

Arduino IDE was selected because it provides a simple and accessible programming environment for ESP32-based boards. It also supports libraries such as ESP32Servo, which simplifies servo motor control.

The schematic was created in KiCad to define the electrical connections between the microcontroller, servo connectors, external power input, filtering capacitor, and ground reference.

This step is essential because the schematic represents the logical structure of the electronic system. If the schematic is incorrect, the PCB layout will also contain errors.

After completing the schematic, I assigned footprints to each component. A footprint represents the physical shape and pad arrangement of a component on the PCB.

Correct footprint assignment is important because an incorrect footprint can cause fabrication or assembly problems. For example, a connector footprint must match the real connector spacing.

The PCB layout was created in KiCad PCB Editor. In this stage, the board outline was defined using the Edge.Cuts layer, and the components were placed according to functionality and accessibility.

The XIAO ESP32-C3 was positioned in a central location, while the servo connectors and power input were placed near the edges to make wiring easier during testing and integration.

PCB routing was performed by connecting the pads according to the nets defined in the schematic. The routing strategy focused on keeping traces short, clean, and easy to inspect.

Power traces were made wider than signal traces because the servo motors require more current than logic signals. I also avoided sharp 90-degree angles to improve the quality and reliability of the routing.

A ground plane was added to improve electrical stability and provide a better current return path. The filled zone was assigned to the GND net and applied around the board.

The ground plane helps reduce electrical noise, improves current return, and supports stable behavior of the electronic circuit.

The Design Rule Check was used to inspect the PCB before fabrication. This verification step helped identify possible clearance problems, overlapping pads, unconnected nets, and routing errors.

Running DRC before fabrication is important because it reduces the risk of producing a board with electrical or manufacturing problems.

The 3D Viewer was used to inspect the final board visually. This tool helped verify component placement, connector orientation, board dimensions, and possible mechanical conflicts.

This final visual inspection allowed me to confirm that the board was ready for manufacturing file generation.

After completing the layout and verification, I generated the manufacturing files. These files are required to fabricate the PCB using digital fabrication equipment or external PCB manufacturing services.

• I learned the complete EDA workflow using KiCad.
• I learned how to create and organize an electronic schematic.
• I understood the importance of correct footprint assignment.
• I practiced PCB routing strategies for power and signal traces.
• I learned how to use a ground plane to improve electrical stability.
• I understood the importance of ERC and DRC verification.
• I connected simulation, firmware, and hardware design in one workflow.
• I improved my technical documentation following Fab Academy standards.

The following hero shot presents the final result of my Electronics Design practice. This image documents the completed PCB design and represents the integration of schematic design, PCB layout, routing process, fabrication preparation, and electronic validation developed during Week 06.

This week’s assignment allowed me to understand the complete workflow involved in electronics design, from the initial circuit concept to the preparation of a PCB ready for fabrication. Through the use of KiCad, I developed skills related to schematic creation, footprint assignment, PCB routing, ground plane generation, design rule verification, and manufacturing file preparation.

The integration of the XIAO ESP32-C3 with two servo motors helped me understand the relationship between embedded programming and hardware design. By validating the system first in Wokwi and later preparing the PCB layout in KiCad, I was able to verify the importance of simulation before fabrication in order to reduce errors and improve reliability.

The group assignment also reinforced the importance of using laboratory equipment such as the multimeter and oscilloscope to analyze and validate electronic systems. Observing real electrical signals and voltage behavior helped strengthen my understanding of embedded electronics and practical debugging techniques.

Overall, this assignment improved my knowledge in electronic design, PCB development, embedded systems, simulation workflows, and technical documentation standards required in Fab Academy. The experience gained during this week will be valuable for future assignments and for the implementation of custom electronics in my final project.