Dual-Board ESP32 Power PCB Design -- 2

@amelectronics

I am a skilled and reliable Embedded Systems Engineer with over 6 years of hands-on experience in Arduino, ESP32/ESP8266, and microcontroller-based development. I specialize in designing efficient, stable, and scalable embedded solutions, turning ideas into fully functional hardware-software systems. I have a strong background in electronics, sensors, communication protocols (UART, I2C, SPI, MQTT, WiFi, BLE), and real-time embedded systems. My development approach focuses on clean, well-structured, and well-documented firmware, ensuring long-term reliability and easy maintenance. I also provide thorough testing, debugging, and performance optimization, including power efficiency improvements where required. I am a detail-oriented engineer with strong problem-solving skills and extensive experience in hardware debugging and firmware optimization. Beyond technical expertise, I value clear communication, meeting deadlines, and maintaining high client satisfaction. I work closely with clients to fully understand project requirements and deliver high-quality results. Pricing is flexible and can be discussed based on project scope and complexity. I am open to both short-term and long-term projects. Let’s work together to build a professional, reliable, and efficient embedded system for your needs.

@mairajali11

With my extensive background as an Electrical/Electronics Engineer and PCB Designer, specifically focusing on circuit design and embedded systems, I am confident in my ability to deliver the exacting standards you require for the smart-helmet cleaning kiosk. Over the past eight years, I have honed my skills using several software tools such as Eagle, Altium, KiCAD and EasyEDA. Your project will be no different. Additionally, my certification as a professional EasyEDA designer only proves my commitment to achieving high-quality results. Safety is an absolute priority for your product and I do not take this lightly. I have significant experience working with high-voltage hardware and designing for mixed-signal applications like the ESP32. This includes ensuring proper isolation, surge protection, and efficient step-down conversion – all fundamental aspects of the project at hand. In addition to delivering complete schematics, PCB layouts and manufacturing files, I also provide validatory documentation outlining how to test isolation and surge tolerance to ensure compliance with stringent safety regulations. As a top-ranked freelancer in my field, I have a proven track record of delivering projects within the set timelines while preserving quality standards. Thank you for considering my skillset; let's turn your concept into an efficient reality!

@Mahmoud00Ibrahim

Hi, This project combines high-voltage power design with sensitive control electronics, which makes it both safety-critical and technically demanding—especially with 230V AC loads, thermal considerations, and isolation requirements alongside an ESP32 control stage. I have solid experience in mixed-signal and power PCB design, including multi-board architectures, proper isolation (creepage/clearance), and reliable interfacing between high-power loads and low-voltage MCUs. I can structure the system into a robust two-board solution (power + control) ensuring safe operation, noise immunity, and manufacturability. I’ll also focus on selecting well-supported, production-ready components with proper protections (surge, thermal, and fault handling), so your manufacturer can proceed without redesign. Estimated timeline: 7–10 days for full schematic, layout, and manufacturing files. Pricing is flexible, as my priority is delivering a clean, reliable, and production-ready design that meets your safety expectations. Happy to discuss details and preferred tools (Altium / KiCad) to move forward.

@ahmedy607

Hi, This aligns well with my experience in mixed-signal and high-voltage PCB design with ESP32-based systems. I’ll develop a robust two-board solution: a dedicated high-power board for the 230V AC loads and a separate low-voltage control board for the ESP32 and logic. The design will prioritize safety with proper isolation, creepage/clearance, surge protection, and reliable AC-DC conversion to stable 12V/5V rails. I’ll ensure clean separation between noisy and sensitive sections, proper driver stages for relays/SSRs, and a layout ready for manufacturing without rework. You’ll receive full schematics, PCB layouts, fabrication files, BOM with approved components, and a brief DFT note covering isolation, surge, and thermal validation. Happy to review your concept and propose component choices and architecture before starting. Best regards, Ahmed

@CyberSasu

With a background in Electronics, Embedded Systems, and PCB Layout, I have the comprehensive expertise and capability needed to create the dual-board ESP32 Power PCB for your smart-helmet cleaning kiosk. My proficiency with mixed-signal, high-voltage hardware design makes me an ideal candidate for this project. And given that safety is of paramount importance, my experience incorporating robust surge protection features on every line ensures your design not only meets but exceeds safety standards. My focus on building scalable solutions would mean that I ensure your design can be efficiently produced by your contract manufacturer without further edits. I am comfortable using Altium, KiCad, and other equivalent tools you may prefer. Furthermore, my familiarity with various components and technologies will enable me to suggest a component lineup that balances cost efficiency, availability as well as regulatory requirements.

@nevorek

Good day. I have experience in creating food-vending machine with using high-voltage circuits. If need, i can prove with. For your system i need little more information about needed board/board-set and i'll set accurate terms.

@ThynkLoop

Hi, I can help you design a dual-board ESP32-based control system for your smart helmet cleaning kiosk, ensuring proper isolation, safe power handling, and reliable control of high-power AC loads. I have experience in embedded systems and PCB design, including mixed-signal and power electronics. I will focus on separating high-voltage and low-voltage sections, implementing proper protection, and delivering a clean, manufacturable design. Scope: *Complete schematic design for control board (ESP32) and power board *High-voltage AC load control *Safe power architecture *Isolation design *Integration of peripherals Deliverables: *Dual-board schematics *PCB layouts *Gerber, drill, and assembly files *BOM with suggested components *Basic test and validation notes Approach: *Design control board based on ESP32 reference *Develop power board with proper isolation and protection *Ensure safe routing for high-current and high-voltage sections *Separate noisy and sensitive circuits *Validate design using DRC and safety guidelines I will ensure a stable and practical design suitable for prototype manufacturing.

@robertbedao

I'd love to take this on — your emphasis on clear communication and punctual delivery matches exactly how I work. Here's how I'd structure the project across 9 days: • Milestone 1 (Day 1–3) — Discovery & Planning: I align fully on your goals, tools, and expectations, and deliver a confirmed action plan before any execution begins. • Milestone 2 (Day 4–6) — Core Execution: The primary deliverable is built and submitted for your review, with a mid-project update so you're never left guessing. • Milestone 3 (Day 7–9) — Final Delivery: Revisions, final polish, and a clean handoff with a short summary of everything completed.

@aryanm901

ESP32 Expertise: Deep experience with ESP32 GPIO level-shifting and Wi-Fi stability in noisy environments. Robotics Logic: My background as a Senior Robotics Engineer ensures I understand the duty cycles and thermal demands of driving multiple actuators and heaters simultaneously. Senior Oversight: I don't just "make it work"; I design for DFT (Design-for-Test), ensuring your first prototypes can be verified for thermal performance and isolation tolerance immediately.

@charlesw554

Hello, I am an experienced hardware engineer with a strong background in designing high-reliability control and power systems for safety-critical applications, including medical and industrial equipment. In previous projects, I have developed multi-layer PCB solutions that integrate microcontrollers like the ESP32 with high-current loads such as heaters and UV lamps, ensuring proper isolation and surge protection in compliance with relevant safety standards. My approach involves creating a two-board layout similar to your concept, with detailed attention to creepage and clearance distances to meet IEC 60601 or UL standards, backed by thorough simulation and testing. I have successfully delivered complete schematics, PCB layouts, and manufacturing-ready files for similar high-voltage, mixed-signal products, with a proven BOM that balances cost and availability while maintaining regulatory compliance. With extensive experience in safety assurance, I will include a comprehensive design-for-test document to facilitate verification of isolation, surge tolerance, and thermal performance during prototype validation. I am confident in my ability to meet your specifications and will do my utmost to complete this project to your full satisfaction, leveraging my expertise to ensure a robust, certifiable product.

@tymsolutions

Hi, I can help you turn your smart-helmet cleaning kiosk into a safe, factory-ready two-board PCB set built around ESP32 control and high-power AC load handling. I have strong experience designing mixed-signal hardware combining Wi-Fi MCUs with heaters, UV systems, motors, and industrial peripherals, with a focus on isolation, surge protection, and production reliability. I’ll implement a two-board architecture: a high-voltage power board for the 230V loads (2 kW heater, fog steriliser, UV lamps) and a separate low-voltage control board hosting the ESP32, level shifting, MOSFET drivers, RGB control, fans, and magnetic locks. Proper isolation using opto/isolated drivers, defined creepage/clearance, and surge protection (MOVs, TVS, fusing, inrush control) will be included. Clean AC-DC conversion to 12V and 5V rails will be designed with thermal and EMI considerations. The design will be optimised for manufacturing with clear safety spacing, modular connectors, and components selected for availability and regulatory compliance. I will also include test points and provisions for validation of isolation. Deliverables: • Complete annotated schematics for both boards • Fully routed PCB layouts with clearance compliance • Gerber/ODB++, pick-and-place, and drill files • Consolidated BOM with alternates and availability notes

@saaraswataroy

I have worked on several mixed high - low voltage circuit designing and proven work, especially in esp32 where a motor was controlled using high voltage through pcb drivers and esp32 was used as the main controlled, it had separated high and low voltage sides in the same pcb so I think I can deliver the requirements very fast and accurately as I already have templates for what you are asking.

@namitj2

I have 2 years of experience in High RF, IP67 rated designs incorporating defense grade actuation. I have worked on reverse engineering and BMS designs as well. You can refer on to (Namit Jain electromechanical engineer) on google for more.

@karann86

Hello, I’m Karan Nahata, Director at Krashak Innovative Solution Pvt. Ltd., with experience in embedded systems, high-power interfacing, and industrial-grade PCB design. Your requirement for a safe, production-ready ESP32-based control system aligns well with my expertise. I understand the critical need for robust isolation, surge protection, and safe AC load control in a commercial product handling 230V mains with loads like heaters, UV lamps, and fog sterilizers. My approach: Two-board architecture: isolated power board (AC, high-current) + control board (ESP32, low-voltage logic) Strong isolation using optocouplers/isolated drivers between logic and mains Reliable switching via SSRs/relays with proper snubber and protection circuits Surge protection (MOVs, TVS, fuses) and EMI-conscious layout Efficient AC-DC conversion to stable 12V & 5V rails Thermal-aware design for high-power sections Clean routing with proper creepage/clearance for safety compliance Deliverables: ✔ Complete schematic (annotated) ✔ PCB layouts for both boards (DFM-ready) ✔ Gerbers, pick-and-place, drill files ✔ BOM with alternates (cost + availability optimized) ✔ Design-for-test notes (isolation, surge, thermal validation) I’ve worked on ESP32-based IoT systems, motor/control hardware, and real-world deployable devices, focusing on reliability and manufacturability. I’m comfortable with iterative reviews and tools like KiCad/Altium. Let’s discuss your timeline and finalize a robust design.

@Bhargav99786

With a strong engineering background and profound knowledge in working with ESP32, the core component of your smart-helmet cleaning kiosk, I am fully equipped to tackle the precise and specialized task you require. Throughout my career, I have successfully executed over 50 custom PCB designs, including complex multi-layer systems similar to your dual-board design requirement. My proficiency extends beyond hardware engineering. In line with your project needs, I have ample experience handling mixed-signal high-voltage hardware containing ESP32 or a similar MCU. With this, I bring to the table an unrivalled understanding of PCB design and mixed power domains for robust surge protection and clean step-down conversion as detailed in your project description. Having successfully delivered over 15 projects worldwide across diverse domains, I've proven my ability to amalgamate different components into a cohesive whole. For your project, this means effectively integrating not only high-power AC loads but also low-voltage peripherals while ensuring proper safety isolation in accordance with regulatory approvals. .