Brick Sound Kit
Cannot show the entire design or circuit board due to an NDA
Project Overview
I was approached by a Boston University alum who, with his son, had an idea to add sound effects while playing with LEGOs. Nine months and several prototypes later we launched a Kickstarter campaign with a fully finished, production ready product. Our team was split between the Boston University Electronic Design Facility working on software and hardware (me) while the mechanical component was through PlusLabs in Cambridge. The end result is a fantastic looking product that kid's can't help but smile when playing with.
My Role:
Electronics Lead
From an idea to a production ready product, as the primary schematic and PCB engineer.
My direct contributions are:
Idea to schematic
Turning a project goal into physical components in a schematic.
Schematic to PCB layout
Daily communication with mechanical team to ensure the correct formfactor with constantly changing dimensions and mounting locations.
PCB design for easy manufacturing and high quality performance.
Programming in C++
I provided a complete skeleton structure for the microcontroller code, and worked closely with the software team to ensure compatibility and correct processing.
Ensure re-programmability
One of the cornerstones of this project is its ability to be easily reprogrammed via the Arduino IDE. Achieved through an FTDI connector near the battery to be unobtrusive during play yet easy to access when wanted.
Several prototype iterations
Debugging after the first prototype run, including design changes like going from example to consumer friendly buttons, and cleaning up appearance of the PCB.
Preparationfor mass-production
Created a method for mass programmability on assembly line with a card edge connector and custom box to test if the PCBs worked in under 20 seconds.
Requirements
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Sense motion, send data to phone real-time
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Low power and smart shut-off capable
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Open source & reprogrammable via Arduino
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Fit in a child's hand comfortably
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Under $30 total BOM (bill of materials) cost
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Design for manufacturing efficiency
Highlights
I worked independently on the board's electronics (with assistance from the EDF director Eric) while working closely with the software and hardware teams. Constant communication with the mechanical team at PlusFab was essential to ensure proper fit between the PCB and enclosure.
To plan for mass-production I connected with Sourcing Overseas, as I knew the quality they provided. They gave insight on how to streamline the production process to minimize costs as well as rough estimates to use for our Kickstarter campaign.