PUBLISHED
August 2025
CATEGORY
PCB / Hardware
companies involved
R&D
Solar-Powered IoT PCB – ESP32 Platform with Bluetooth
01. The challenge and the solution
For a project covered by confidentiality it was necessary to develop a dedicated electronic board based on ESP32, able to:
- communicate through Bluetooth,
- battery operated,
- recharge via solar panels,
- ensure reliable operation in the field.
The solution was to design a custom PCB which integrates:
- a ESP32 microcontroller for logical management and connectivity,
- a battery controller and management of charging from solar panels,
- protection and signal conditioning circuits for external sensors and peripherals.
The main goal was not just to “get the prototype working”, but to create a hardware base scalable and producible, suitable for subsequent product evolutions.
“Everyone is good at putting teachings into practice, but only the best learn by themselves.”
– EMR
02. The work process
The development of the card required in-depth work on multiple levels.
Technical analysis and study of components
- Detailed study of the microcontroller documentation and power management components (battery chargers, solar controllers, protections, regulators, etc.)
Evaluation of the different solutions available to optimize:
- energy consumption,
- stability of solar charging,
- dimensions and production costs.
Schematic Design & PCB Layout
Realization of the complete wiring diagram of the card, including:
- logic section (ESP32 and interfaces),
- power and charging section,
- battery management, sensors and external connectors.
Design of the PCB layout following best practices for:
- signal integrity,
- power routing,
- noise reduction,
- optimal positioning for antenna and critical components.
- Generation of the Gerber files and production files for suppliers.
- Prototyping, testing and iterations
Production of the first physical prototypes of the board.
- Field tests in real conditions to verify:
- stability of Bluetooth communication,
- solar charging behavior,
- battery life,
- system response with external sensors and wiring.
Based on the results, development of several later versions of the PCB, with improvements aimed at:
- optimize layout and components,
- simplify assembly and wiring,
- increase overall reliability.
Supply chain & components
Search for suitable suppliers For:
- PCB and assembly,
- main components (IC, passives, connectors),
- external cables, sensors and accessories connected to the board.
Optimization of the BOM (Bill of Materials) to ensure availability, sustainable costs and production continuity.
03. The result
The result is a IoT hardware platform:
- based on ESP32 with Bluetooth,
- battery powered with charging from solar panels,
- designed following best practices PCB design and power management,
- validated via real field tests and more iterations of improvement.
This PCB represents a key piece for the confidential project of which it is part and demonstrates the ability to address all phases in a structured way:
from study of the documentation at the design, from the prototyping up to the supplier selection for possible mass production.