Mini Projects & Hardware Log

2024 — Present · Hardware & Embedded Designer

Mini Projects & Hardware Log

Custom PCB designs, specialized input controllers, and mechanical mechanisms

A collection of rapid hardware prototypes, custom controllers, and experimental mechanical assemblies built across personal projects and robotics experiments.


1. µController — Custom Unrailed Game Controller

A dedicated handheld controller built specifically for grid-precision tile placement in Unrailed. Engineered a custom 2-layer PCB in KiCad with USB-C, an onboard LiPo charging and boost regulator circuit for portable power, and analog Hall effect sensors for zero-drift magnetic key actuation.

Custom Unrailed Game Controller

2. The 100-Key Macro Pad

An oversized 100-mechanical-switch macro board built for extensive hotkey profiles and hardware shortcuts. Features a custom KiCad matrix PCB, per-key addressable RGB backlighting, an OLED status display for active profile readouts, and reverse-polarity input protection.

100-Key Macro Pad Assembly

3. Friend Tracker — Meshtastic GPS & Digital Compass

A handheld, off-grid LoRa tracking node designed for sharing GPS coordinates without cellular service. Built around an ESP32-S3 and Seeed Wio-E5 LoRa module, paired with a u-blox MAX-M10S GNSS receiver and QMC5883P electronic compass. Laid out in KiCad with curved RF trace routing and housed in a parametric 3D-printed Onshape enclosure.

Friend Tracker Schematic

Custom Schematic in KiCad

Enclosure CAD

Onshape Parametric Housing Enclosure

PCB 3D Render

3D Board Render & Decoupling Validation


4. Differential Swerve — Concentric Bevel Drive Pod

An ultra-compact 3D-printed differential swerve drive module for robotics. Uses two coaxial input shafts and concentric bevel gears to blend drive velocity and steering rotation. Iterated through 4 generations of wrap-around gearboxes, integrated AS5600 magnetic encoders for azimuth feedback, and performed FEA topology optimization on bearing blocks to handle wheel shock loads.

Differential Swerve Assembly

Full Swerve Module Assembly

Bearing Block Design

Direct Load Path Bearing Block

FEA Shape Optimization

FEA Topology Stress Optimization

Gearbox V2

High-Reduction Neo 550 Gearbox

Wrap-around Gearbox V3

Compact Wrap-Around Gear Train

Magnetic Encoder Integration

AS5600 Magnetic Azimuth Sensing

Stack

Embedded & PCB

KiCadRP2040ESP32-S3 / Wio-E5LiPo Boost RegulatorsHall Effect SensorsWS2812B RGBs

Mechanical & CAD

Onshape CADTopology OptimizationFEA Stress AnalysisBevel Gear Kinematics3D Printing