Power board design…
A bit of a rocky version with lyrics at the end…
Recently, we decided to help a client with a custom commercial power board design with a list of criterias..
All to fit in a very tight space…
Board size?
14*28 mm, or .. about 2 keys on the keyboard, side by side…
- Reverse polarity protection.
- 1A Buck/Boost convert to a steady output voltage.
- Battery low capacity indication by through board lead.
- Output overvoltage protection and cutout.

I’m pretty happy with what it came out to be – It’s an absolute tiny board with resistors being 0806 and 1203 sizes.
Untold revisions and headaches later, this is what it looks like…
One of our services is custom board design, and this is another example of one we designed around ESP32.
Specs:
- ESP32, dual core 240MHz, 16M flash, 8M ram.
- Onboard power regulation for 3.3 and 5V
- USD card for data / apps.
- USB for programming, comms and power.
- Separate 5-12V power supply.
- 4 PWM/I2S, analogue/digital IO
- 4 2A 30 V mosfet drive lines (switch/pwm, NMOS)
- IO is 3.3/5V selectable per port\
- 2 serial
- I2 port
- SPI/canbus port (up to 80 Mbit)
- 32 IO (voltage selectable per bank of 8) with interrupt capability and switch rates up to ~800KHz.
- RTC with battery backup
- 2K EEPROM for config / data.
- RGB LED for status
Board design blues
Lyrics:
Verse 1
I woke up Monday morning with a schematic in my hand,
A coffee-stained disaster and a half-forgotten plan.
The op-amp looked offended, the MOSFET gave a sigh,
And the regulator whispered, “Mate, I’m about to fry.”
Chorus
Oh, route it left, route it right,
Keep that ground plane nice and tight.
Vias dancing, traces bend,
DRC says, “Try again.”
Oh, copper here, silkscreen there,
Who put high-speed next to air?
Board layout’s a silly game,
But somehow we ship it all the same.
Verse 2
The datasheet said “simple”, which was clearly just a trap,
Forty-seven footnotes and a terrifying app.
I placed a cap “quite near enough”, or so I boldly thought,
Now the chip emits a squeal like a kettle overwrought.
Chorus
Oh, route it left, route it right,
Keep that ground plane nice and tight.
Vias dancing, traces bend,
DRC says, “Try again.”
Oh, decouple every pin,
Then decouple them again.
If it oscillates at night,
Blame the layout, not the spite.
Bridge
Silkscreen says “R13”, but the resistor’s gone abroad,
The test point’s under plastic and the USB is flawed.
The mounting holes are perfect, though they miss the case by three,
And the intern says, “It worked at home,” then quietly makes tea.
Verse 3
The autorouter had a go and made a modern art display,
A ninety-degree zigzag in a very cursed ballet.
The differential pair split up and now they barely speak,
While the clock line’s doing karaoke seven times a week.
Final Chorus
Oh, route it left, route it right,
Keep that ground plane nice and tight.
Vias dancing, traces bend,
DRC says, “Try again.”
Pour the copper, check the stack,
Send the gerbers, don’t look back.
When the magic smoke takes flight,
We’ll call it “revision two” tonight.

Every now and then, one may wish to have had a simple script to check out or 
Using the service from