Cursor AI assistance for Week 14 Day 3 electrical integration and fabrication documentation, including TFT display wiring documentation, board design updates, fabrication integration methods, and Day 3 content updates.
Full Conversation
UserUnknown
follow the general guidelines:
— for each image or video add a caption and description.
— make all the text professional and succinct without losing key details
— make the information as organized and as aesthetically pleasing as possible
— don't just take my notes from the prompt, refine it before putting it on the page
-- for anything step by step, make the steps clear and easy to follow
specific tasks: (all in week14.html)
1-- update electrical integration section with the content in this chat (refine it as electrical integration methods to spirally develop) -- ignore the images in the chat
heading in to mill, design, iterate!
does tft led go to 5v for both 1.8 inch and 2.4 inch? this video does led at 3.3v and vcc at 5v
Guide to 1.8 TFT Display with Arduino | Random Nerd Tutorials
In this guide we're going to show you how to use the 1.8 TFT display with the Arduino. You'll learn how to write text, draw shapes and display images on the screen using Arduino. We'll also show you what you need to do to use the SD card slot that comes built-in with the display.
ESP32: TFT Touchscreen - 2.8 inch ILI9341 (Arduino) | Random Nerd Tutorials
Get started with the TFT LCD Touchscreen Display with the ESP32 board. This TFT Touchscreen display with 2.8 inch (240×320 px) comes with the ILI9341 driver.
Seeed studio XIAO-ESP32-C3 connected to an ILI9341 SPI TFT display
by Floris Wouterlood — March 2, 2024– Summary — An incredibly small, yet powerful and handy microcontroller board is the XIAO-ESP32-C3 made by seeed studio. We wire this board her…
TFT added to camera-accelerometer-pulse oximeter board
2 files
Download all
Screenshot 2025-12-12 at 10.56.14 PM.png
Screenshot 2025-12-12 at 10.56.36 PM.png
Saleem Aldajani
11:05 PM
Annnd it fits (the oled is still there in case it doesn't work for any reason)
2 files
Download all
Screenshot 2025-12-12 at 11.01.50 PM.png
Screenshot 2025-12-12 at 11.04.41 PM.png
11:05
:zzz:
11:08
(need to figure out power inside the watch tomorrow, might just cut a hole and feed a wire -- i did see ultraslim powerbanks on amazon for later)
11:10
tomorrow morning i'll update day 3 with fabrication integration work so far before coming to lab to mill, solder, print
11:10
if there's time ill do the molding designs before 11 once documentation is up to date
-- used source for tft wiring to esp32 xiao (put links to the other sources i read too just highlight this one as the one i used for pinout mapping to esp32 xiao)
2-- add a new section for day 3 fabrication integration with these subsections
2.1. 2d fabrication: laser cutting and vinyl cutting
the laser cut acrylic was updated in day 2 (add link) and shown in the integrated watch assembly
2.2. 3d printing rigid and flexible components
the bands were printed out of tpu, should print the case out of tpu too so the interlock parts fits in better. other print details in day 2 (add link). embed these images and/or videos:
printed-tpu-band-1.jpeg
printed-tpu-band-2.jpeg
band-closes.jpeg
printed-rigid-dock.jpeg
assembled-rigid-dock.jpeg
spring-loaded-interlock.jpeg
2.3. milling single and double-sided boards
milling the aging clock watch board worked, i upgraded the design for tft and will mill the new design and test it with the base oled version. embed these images and/or videos:
milling-aging-clock.mp4
locate-tool-probes-z.jpeg
milling-aging-clock-2.mp4
milling-aging-clock-3.mp4
completed-aging-clock-mill.mp4
vacuuming-aging-clock-mill.mp4
removing-aging-clock-mill.jpeg
milling the base amplifier board failed due to polygon pour isolate default set to 0, we changed it to 32 on the back and it worked. when the shop closed, i upgraded it to also include a tft screen, so will remill the base design and tft versions together and test both. embed these images and/or videos:
milling-mirrorage-1.mp4
milling-mirrorage-2.mp4
failed-milling.jpeg
milling-mirrorage-3-failed.mp4
fixturing-second-side.jpeg
second-side.mp4
milling-backside.mp4
fixed-isolate-32mil.jpeg
fixed-isolate-32-mil.mp4
2.4. integrating fabrication
the watch board fits in the watch case, the acrylic display fits too. need to drill holes for mounting electronics and route holes for power. embed these images and/or videos:
agingclock-integration.jpeg
integrated-watch-board.jpeg
assembled-bands-with-clip.jpeg
spring-loaded-interlock.mp4
spring-loaded-interlock.jpeg
i made sure the upgrades also fit, so the tft watch board fits with the tft. the base and tft loadcell-speaker mirrorage board fit in/on the gripper enclosure, will also need to drill holes for mounting and add hooks for the load cell wire to the hx711 mounted on the board and route power. embed these images and/or videos:
upgrades:
tft to aging clock board:
upgraded-tft-aging-clock.jpeg
upgraded-tft-aging-clock-board.jpeg
upgraded-tft-aging-clock-board-schematic.jpeg
upgraded-tft-mirror-age.jpeg
upgraded-tft-mirror-age-schematic.jpeg
tft to mirrorage board:
base-mirrorage-board.png
tft-mirrorage-board.png
integrated-demo-v20.png
3. update critical path analysis based on what we have done in the page so far after fully updating tasks 1 and 2
AssistantUnknown
Reviewing week14.html to understand the structure.
Checking for additional images and reviewing the electrical integration section:
Updating the electrical integration section and adding the Day 3 section. Creating a task list:
Updating the electrical integration section with TFT wiring information:
Final project integration week focused on bringing together all subsystems into a cohesive MirrorAge system, completing documentation, and preparing for final presentation.
Final integration week focused on bringing all subsystems together, completing hardware fabrication, firmware integration, and documentation for the MirrorAge system presentation.
The act of bringing something to a conclusion or ending in a decisive manner. The ability to efficiently finish tasks and projects with a goal-oriented mindset.
Wednesday
Morning
Publish system integration plan on website
Update weekly assignment sections on final project page (weeks 10-13)
Link final project design files
Update reflections and learnings
Update picture of prism holder
Add final pictures to Slack canvases
Create schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Start CAD model of system
Place final order
Afternoon & Evening
Design:
Boards: Combine OLED screen/accelerometer with pulse oximeter board in a new board (maybe upgrade to small TFT as minor)
Boards: Speaker board with realtime amplifier and TFT (on the load cell fixed board)
Band: Mold design
Cases: 3D print mountable cases for the boards
Integrate designs into final CAD
Document design
Finish CAD model of system
Thursday
Fabricate
Milling boards
Print mold and cast band
Print cases
Solder
Solder components on milled boards
Connect boards with wired (and wireless connection codes)
Finishing
Mirror on screen (easy way with the film)
Documentation
Document fabrication
Friday
Programming
Board level codes
Server level codes
Documentation
Document codes
Completion
Finish anything else
Saturday
Programming & Testing
Demo integrated system
Test integrated system
Documentation
Document testing and evaluation
Review and complete documentation (list of questions)
Make the video by collaging documentation
Sunday
Fill up any gaps
Prepare demo on tensegrity table
Finalize 1-slide
Work on minors
If done, work on if there's time
Monday Morning
Transport demo on tensegrity table
Fill up any gaps
Work on minors
Specific Tasks to Complete This Week
Major Tasks
CAD model of system
Speaker board with realtime amplifier
Combine screen/accelerometer with pulse oximeter board in a new board
Mold and cast band
Design and fabricate casing (print)
Schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Serial connection between pulse oximeter and tiny blinking heart for BPM (BPM from IR, SpO2 from delta)
Combine multiple boards on the same WiFi (switching tabs is easy way, board hosting the webpage querying and update or Python-based server somewhere where everything posting data, Raspberry Pi)
Put+program everything together according to the above (with WiFi for now)
Summary slide and one-minute video for documentation
Conception
Construction
Operation
Minor Tasks
Program microphone/speaker
Fix reaction time delay code
Program LoRa connection
Fix OLED plus WiFi issue
Upgrade to TFT (SPI is very straightforward, design board with either SPI or OLED connection)
Fix heart engraving to center
Engrave K9 glass mirror if it arrives
RD and IRD isolation slit (maybe wick and then cut)
Do the calibration curve for the load cell
Finish cardboard laser cutter origami big mirror frame
If There's Time
Moving base of mirror
Orders
Raspberry Pi Zero (or server host, do some research)
Presentation
Aim for 2.5 minutes because Neil will ask questions
Generally no slides except for 1 open summary slide (have backup slides in case questions come up!)
Related: See the Development Timeline on the final project page for the overall project schedule.
Day 1: Design Integration
Initial system integration work focused on subsystem validation, CAD model consolidation, and design backbone acquisition for band integration.
Subsystem Validation
Conducted comprehensive testing of all subsystems to ensure proper functionality. Identified and resoldered any defective joints, verifying that each subsystem operates correctly before proceeding with full system integration.
CAD Model Consolidation
Exported CAD models of all PCBs in the final design and imported them into a unified CAD assembly. This consolidated model provides a complete view of the system's mechanical integration and spatial relationships.
Integrated CAD Model: Exploded isometric view of the complete system assembly, including all PCBs (pulse oximeter, OLED/accelerometer, speaker/amplifier), main housing with transparent enclosure, and wearable band components. The model shows the spatial relationships between electronic subsystems and mechanical structures, enabling precise integration planning.
Band Design Backbone
Acquired CAD design files for Apple Watch form factor integration, enabling compatibility with existing band designs and standardized watch components. This provides a proven mechanical foundation for the wearable subsystem.
Resuming the daily schedule tomorrow with parallel work streams prioritized according to the critical path. Tasks that cannot be completed during scheduled days will be shifted to buffer days on Saturday and Sunday to maintain project momentum.
Day 2: Electrical and Mechanical Integration
Physical integration of subsystems into the complete demo table assembly, including mechanical component fabrication and electrical board consolidation.
2.1 Mechanical Integration
Mechanical design integration now includes the complete demo table with precise placement of the MirrorAge handgrip subsystem and the aging clock subsystem. The integrated assembly provides a unified platform for system demonstration and testing.
Complete Demo Table Assembly: Integrated mechanical design showing precise placement of the MirrorAge handgrip subsystem and aging clock subsystem on the demo table. The assembly demonstrates the spatial relationships and mounting configurations for both subsystems within the unified demonstration platform.
3D Additive Manufacturing
All 3D additive mechanical components were printed for rapid iterative development. The fabrication process required specific print settings and support strategies for different components:
Printing Initiation: 3D printer starting the fabrication process for mechanical components
Casing Print: Casing component during 3D printing process
Print Configuration Requirements:
Casing: Required organic support structures for complex overhangs
Dock: Required brim adhesion to prevent warping during printing
Bands: Printed using TPU (Thermoplastic Polyurethane) material for flexibility (will spiral into molding and casting in future iterations)
Organic Support Configuration: Slicer settings showing organic support structures for the casing component
Brim Addition: Dock component with brim added to prevent warping during printing
Casing with Organic Support: Printed casing component showing organic support structures
TPU Bands: Flexible wearable band components printed using TPU material
Print Failures and Iteration
Failed Casing Print: Initial casing print failure requiring support structure adjustments
Failed Dock Print: Dock print failure due to warping, resolved with brim addition
Printing Failures: Documentation of various print failures encountered during iterative development
Printing Progress: Successful components showing iterative improvement in print quality
2D Subtractive Manufacturing
The first 2D subtractive mechanical component was debugged and fabricated. The display face component required exporting a DXF of the full face to laser cut an acrylic display that fits the casing precisely. The original display part face was too small because it was filleted, so the edges of the aging clock body were traced and exported for accurate laser cutting.
Laser Cutting Process 1: Initial laser cutting of acrylic display component
Laser Cutting Process 2: Continued laser cutting operation for display face
Acrylic Display Fit: Laser-cut acrylic display component precisely fitted into the casing, demonstrating successful integration of 2D subtractive and 3D additive manufacturing components.
2.2 Electrical Integration
Electrical design integration now combines the accelerometer/camera board with the pulse oximeter board into a single unified design that fits inside the casing. The integrated board may be upgraded to include a small TFT screen in a future iteration if space constraints allow.
Board Design Evolution
Initial Board Design: First integrated board design showing size constraints relative to casing dimensions
Board in Casing: Revised board design fitted within casing dimensional constraints
Final Integrated Board Design: Complete aging clock board design combining accelerometer/camera functionality with pulse oximeter sensors in a single unified PCB layout optimized for casing fit and component placement.
TFT Display Integration
Both the aging clock watch board and the MirrorAge load cell-speaker board have been upgraded to include TFT displays for enhanced visual feedback. The displays use SPI communication for straightforward integration with the ESP32-S3 XIAO microcontroller.
TFT Display Wiring: Pin connection diagram showing SPI interface connections between TFT displays and ESP32-S3 XIAO microcontroller for both watch and MirrorAge boards.
MirrorAge Amplifier Board Design
The MirrorAge amplifier board integrates a real-time audio amplifier with load cell interface and TFT display. The base design includes the amplifier circuit and HX711 load cell interface, with an upgraded version adding the 2.4" ILI9341 TFT display.
Base Amplifier Board: Initial design with real-time amplifier and HX711 load cell interface
Base Board Layout: PCB layout showing component placement for amplifier and load cell interface
TFT Display Component:
1.8" TFT LCD: ST7735 controller, 128×160 pixels. CAD model reference:
GrabCAD ST7735 Model
TFT-Integrated MirrorAge Board: Upgraded PCB design incorporating the 2.4" ILI9341 TFT display alongside the amplifier and load cell interface, enabling visual feedback for grip strength measurements.
Aging Clock Watch Board Design
The aging clock watch board combines pulse oximeter sensors, accelerometer, and camera functionality. The base design uses an OLED display, with an upgraded version incorporating a 1.8" ST7735 TFT display for enhanced visual feedback.
Base Aging Clock Board: Initial design integrating pulse oximeter, accelerometer, and camera with OLED display for wearable watch form factor.
Board Fabrication and Integration
The first version of the aging clock board was milled. The initial board did not fit the casing, requiring either casing adjustment and reprinting, or milling a new miniaturized board with shrunken electronics. Both approaches are being evaluated. The MirrorAge board design has been completed for both base and TFT-integrated versions, ready for milling and testing.
Milled Integrated Board: First version of the integrated aging clock board after PCB milling, showing component placement and routing
Board Fit Test: Milled board nearly fitting in casing, demonstrating the need for dimensional optimization
Board Deflection Fixing: Process of addressing board deflection and mechanical fit issues during integration testing, demonstrating iterative refinement of the electrical-mechanical interface.
Critical Path Analysis
Project management view of the integration schedule, showing task dependencies, critical milestones, and current progress status.
Critical Path Tasks
Phase 1: Design & DocumentationMOSTLY COMPLETE
CAD model consolidation and system integration design ✓
PCB design: combine OLED/accelerometer with pulse oximeter ✓
Demo table integration design with subsystem placement ✓
PCB design: speaker board with realtime amplifier and TFT (MirrorAge board)
Band mold design
3D printable cases for board mounting ✓
System schematic documentation (wired and wireless)
Website documentation updates (Day 1 & Day 2) ✓
Phase 2: FabricationIN PROGRESS
PCB milling: aging clock board milled (fit optimization in progress)
Component soldering (pending board fit resolution)
Band mold printing and casting
3D printing of board cases (casing, dock, bands) ✓
2D subtractive: laser-cut acrylic display ✓
Mirror film application to screen
Phase 3: Integration & ProgrammingPENDING
Board-level firmware integration
WiFi network coordination between boards
Server-level code development
Serial communication: pulse oximeter to heart display (BPM/SpO2)
System wiring and wireless connection setup
Phase 4: Testing & DocumentationPENDING
Integrated system testing and validation
System evaluation and cost documentation
One-minute video production (conception, construction, operation)
Summary slide preparation
Final documentation review and completion
Current Status
✓
Completed:
Subsystem testing and validation, CAD model consolidation, demo table integration design, aging clock PCB design (accelerometer/camera + pulse oximeter), 3D printing of mechanical components (casing with organic support, dock with brim, TPU bands), laser-cut acrylic display, initial board milling
→
In Progress:
Board fit optimization (casing adjustment vs. miniaturized board), MirrorAge board design (handgrip + speaker + TFT), data integration methods documentation (serial, WiFi, MQTT spiral development)
○
Upcoming:
Component soldering, band mold printing and casting, firmware integration, WiFi/MQTT network setup, system wiring, integrated testing, final documentation
Buffer Days (Saturday & Sunday)
Tasks that cannot be completed during scheduled weekdays will be shifted to Saturday and Sunday buffer days. This ensures the critical path remains on schedule while allowing flexibility for unexpected delays or additional refinement work.
Data Integration Methods to Spirally Develop
Progressive development approach for integrating sensor data streams from multiple subsystems, starting with simple serial communication and evolving to wireless network-based architectures.
Method 1: Serial Communication (Easiest)
Direct serial communication through USB cable from computer to microcontroller, using PySerial to stream data. This provides the simplest initial integration path for rapid prototyping and debugging.
Implementation:
USB cable connection from computer to ESP32-S3 microcontroller
PySerial library for Python-based data streaming
Arduino Serial functions for microcontroller-side communication
Configure all microcontrollers as WiFi clients that stream data to a flash web server. This enables wireless communication while maintaining a centralized data aggregation point.
Implementation:
All ESP32-S3 boards configured as WiFi clients on the same network
Central web server (initially laptop-hosted) receives data streams
WiFiClient::write() functions for data transmission
Message Queuing Telemetry Transport (MQTT) provides a lightweight, publish-subscribe messaging protocol ideal for IoT device communication. This approach enables decentralized data exchange between all MirrorAge subsystems, allowing each board to publish sensor data and subscribe to relevant topics for coordinated system behavior.
Server Hosting Strategy:
Initial development and testing will use a laptop-hosted MQTT broker. In a later development spiral, the server will be migrated to a dedicated Raspberry Pi Zero or Raspberry Pi 5 for standalone operation and improved system portability. Paho MQTT library has been successfully tested for ESP32-S3 implementation.
Development will progress through these methods in order of complexity, starting with serial communication for rapid prototyping, then moving to WiFi client architecture for wireless operation, and finally implementing MQTT for advanced decentralized communication. Each subsystem board (pulse oximeter, OLED/accelerometer, speaker/amplifier, load cell) will be integrated progressively, enabling:
Incremental complexity management and early validation
Decoupled communication between subsystems
Real-time data streaming from multiple sensors
Scalable architecture for adding new sensor modules
Flexible server deployment (laptop → Raspberry Pi migration path)
Reflections & Learnings
Reflections and key learnings from the final project integration week.
Key Points
System integration requires careful coordination of mechanical, electrical, and software subsystems
Comprehensive planning and day-by-day scheduling are essential for managing complex integration tasks
Modular design enables incremental testing and validation of individual components before full system assembly
Documentation throughout the integration process supports debugging and future improvements
Final integration week demands focus, organization, and the ability to adapt to unexpected challenges
Contributions
Acknowledgments for contributions and collaborations during the final project week.
Ethical AI Use
Documentation of AI-assisted tasks and tools used during the final project integration week.
📋 General Guidelines: See General Commands for Cursor on the homepage for standard guidelines and commands used consistently throughout documentation development.
Cursor · Project Plan & Weekly Schedule
Comprehensive Cursor AI assistance for outlining the project plan and weekly schedule, including documentation structure, content organization, systematic updates across all week pages and the final project page, media integration, and summary generation workflows.
Cursor AI assistance for Week 14 project integration updates, including Day 2 electrical and mechanical integration documentation, data integration methods refinement, and critical path analysis updates.
Final project integration week focused on bringing together all subsystems into a cohesive MirrorAge system, completing documentation, and preparing for final presentation.
Final integration week focused on bringing all subsystems together, completing hardware fabrication, firmware integration, and documentation for the MirrorAge system presentation.
The act of bringing something to a conclusion or ending in a decisive manner. The ability to efficiently finish tasks and projects with a goal-oriented mindset.
Wednesday
Morning
Publish system integration plan on website
Update weekly assignment sections on final project page (weeks 10-13)
Link final project design files
Update reflections and learnings
Update picture of prism holder
Add final pictures to Slack canvases
Create schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Start CAD model of system
Place final order
Afternoon & Evening
Design:
Boards: Combine OLED screen/accelerometer with pulse oximeter board in a new board (maybe upgrade to small TFT as minor)
Boards: Speaker board with realtime amplifier and TFT (on the load cell fixed board)
Band: Mold design
Cases: 3D print mountable cases for the boards
Integrate designs into final CAD
Document design
Finish CAD model of system
Thursday
Fabricate
Milling boards
Print mold and cast band
Print cases
Solder
Solder components on milled boards
Connect boards with wired (and wireless connection codes)
Finishing
Mirror on screen (easy way with the film)
Documentation
Document fabrication
Friday
Programming
Board level codes
Server level codes
Documentation
Document codes
Completion
Finish anything else
Saturday
Programming & Testing
Demo integrated system
Test integrated system
Documentation
Document testing and evaluation
Review and complete documentation (list of questions)
Make the video by collaging documentation
Sunday
Fill up any gaps
Prepare demo on tensegrity table
Finalize 1-slide
Work on minors
If done, work on if there's time
Monday Morning
Transport demo on tensegrity table
Fill up any gaps
Work on minors
Specific Tasks to Complete This Week
Major Tasks
CAD model of system
Speaker board with realtime amplifier
Combine screen/accelerometer with pulse oximeter board in a new board
Mold and cast band
Design and fabricate casing (print)
Schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Serial connection between pulse oximeter and tiny blinking heart for BPM (BPM from IR, SpO2 from delta)
Combine multiple boards on the same WiFi (switching tabs is easy way, board hosting the webpage querying and update or Python-based server somewhere where everything posting data, Raspberry Pi)
Put+program everything together according to the above (with WiFi for now)
Summary slide and one-minute video for documentation
Conception
Construction
Operation
Minor Tasks
Program microphone/speaker
Fix reaction time delay code
Program LoRa connection
Fix OLED plus WiFi issue
Upgrade to TFT (SPI is very straightforward, design board with either SPI or OLED connection)
Fix heart engraving to center
Engrave K9 glass mirror if it arrives
RD and IRD isolation slit (maybe wick and then cut)
Do the calibration curve for the load cell
Finish cardboard laser cutter origami big mirror frame
If There's Time
Moving base of mirror
Orders
Raspberry Pi Zero (or server host, do some research)
Presentation
Aim for 2.5 minutes because Neil will ask questions
Generally no slides except for 1 open summary slide (have backup slides in case questions come up!)
Related: See the Development Timeline on the final project page for the overall project schedule.
Day 1: Design Integration
Initial system integration work focused on subsystem validation, CAD model consolidation, and design backbone acquisition for band integration.
Subsystem Validation
Conducted comprehensive testing of all subsystems to ensure proper functionality. Identified and resoldered any defective joints, verifying that each subsystem operates correctly before proceeding with full system integration.
CAD Model Consolidation
Exported CAD models of all PCBs in the final design and imported them into a unified CAD assembly. This consolidated model provides a complete view of the system's mechanical integration and spatial relationships.
Integrated CAD Model: Exploded isometric view of the complete system assembly, including all PCBs (pulse oximeter, OLED/accelerometer, speaker/amplifier), main housing with transparent enclosure, and wearable band components. The model shows the spatial relationships between electronic subsystems and mechanical structures, enabling precise integration planning.
Band Design Backbone
Acquired CAD design files for Apple Watch form factor integration, enabling compatibility with existing band designs and standardized watch components. This provides a proven mechanical foundation for the wearable subsystem.
Resuming the daily schedule tomorrow with parallel work streams prioritized according to the critical path. Tasks that cannot be completed during scheduled days will be shifted to buffer days on Saturday and Sunday to maintain project momentum.
Day 2: Electrical and Mechanical Integration
Physical integration of subsystems into the complete demo table assembly, including mechanical component fabrication and electrical board consolidation.
2.1 Mechanical Integration
Mechanical design integration now includes the complete demo table with precise placement of the MirrorAge handgrip subsystem and the aging clock subsystem. The integrated assembly provides a unified platform for system demonstration and testing.
Complete Demo Table Assembly: Integrated mechanical design showing precise placement of the MirrorAge handgrip subsystem and aging clock subsystem on the demo table. The assembly demonstrates the spatial relationships and mounting configurations for both subsystems within the unified demonstration platform.
3D Additive Manufacturing
All 3D additive mechanical components were printed for rapid iterative development. The fabrication process required specific print settings and support strategies for different components:
Printing Initiation: 3D printer starting the fabrication process for mechanical components
Casing Print: Casing component during 3D printing process
Print Configuration Requirements:
Casing: Required organic support structures for complex overhangs
Dock: Required brim adhesion to prevent warping during printing
Bands: Printed using TPU (Thermoplastic Polyurethane) material for flexibility (will spiral into molding and casting in future iterations)
Organic Support Configuration: Slicer settings showing organic support structures for the casing component
Brim Addition: Dock component with brim added to prevent warping during printing
Casing with Organic Support: Printed casing component showing organic support structures
TPU Bands: Flexible wearable band components printed using TPU material
Print Failures and Iteration
Failed Casing Print: Initial casing print failure requiring support structure adjustments
Failed Dock Print: Dock print failure due to warping, resolved with brim addition
Printing Failures: Documentation of various print failures encountered during iterative development
Printing Progress: Successful components showing iterative improvement in print quality
2D Subtractive Manufacturing
The first 2D subtractive mechanical component was debugged and fabricated. The display face component required exporting a DXF of the full face to laser cut an acrylic display that fits the casing precisely. The original display part face was too small because it was filleted, so the edges of the aging clock body were traced and exported for accurate laser cutting.
Laser Cutting Process 1: Initial laser cutting of acrylic display component
Laser Cutting Process 2: Continued laser cutting operation for display face
Acrylic Display Fit: Laser-cut acrylic display component precisely fitted into the casing, demonstrating successful integration of 2D subtractive and 3D additive manufacturing components.
2.2 Electrical Integration
Electrical design integration now combines the accelerometer/camera board with the pulse oximeter board into a single unified design that fits inside the casing. The integrated board may be upgraded to include a small TFT screen in a future iteration if space constraints allow.
Board Design Evolution
Initial Board Design: First integrated board design showing size constraints relative to casing dimensions
Board in Casing: Revised board design fitted within casing dimensional constraints
Final Integrated Board Design: Complete aging clock board design combining accelerometer/camera functionality with pulse oximeter sensors in a single unified PCB layout optimized for casing fit and component placement.
TFT Display Integration
Both the aging clock watch board and the MirrorAge load cell-speaker board have been upgraded to include TFT displays for enhanced visual feedback. The displays use SPI communication for straightforward integration with the ESP32-S3 XIAO microcontroller.
TFT Display Wiring: Pin connection diagram showing SPI interface connections between TFT displays and ESP32-S3 XIAO microcontroller for both watch and MirrorAge boards.
MirrorAge Amplifier Board Design
The MirrorAge amplifier board integrates a real-time audio amplifier with load cell interface and TFT display. The base design includes the amplifier circuit and HX711 load cell interface, with an upgraded version adding the 2.4" ILI9341 TFT display.
Base Amplifier Board: Initial design with real-time amplifier and HX711 load cell interface
Base Board Layout: PCB layout showing component placement for amplifier and load cell interface
TFT Display Component:
1.8" TFT LCD: ST7735 controller, 128×160 pixels. CAD model reference:
GrabCAD ST7735 Model
TFT-Integrated MirrorAge Board: Upgraded PCB design incorporating the 2.4" ILI9341 TFT display alongside the amplifier and load cell interface, enabling visual feedback for grip strength measurements.
Aging Clock Watch Board Design
The aging clock watch board combines pulse oximeter sensors, accelerometer, and camera functionality. The base design uses an OLED display, with an upgraded version incorporating a 1.8" ST7735 TFT display for enhanced visual feedback.
Base Aging Clock Board: Initial design integrating pulse oximeter, accelerometer, and camera with OLED display for wearable watch form factor.
Board Fabrication and Integration
The first version of the aging clock board was milled. The initial board did not fit the casing, requiring either casing adjustment and reprinting, or milling a new miniaturized board with shrunken electronics. Both approaches are being evaluated. The MirrorAge board design has been completed for both base and TFT-integrated versions, ready for milling and testing.
Milled Integrated Board: First version of the integrated aging clock board after PCB milling, showing component placement and routing
Board Fit Test: Milled board nearly fitting in casing, demonstrating the need for dimensional optimization
Board Deflection Fixing: Process of addressing board deflection and mechanical fit issues during integration testing, demonstrating iterative refinement of the electrical-mechanical interface.
Day 3: Fabrication Integration
Comprehensive fabrication integration work combining 2D laser cutting, 3D printing, and PCB milling to create fully integrated subsystems ready for assembly and testing.
2.1 2D Fabrication: Laser Cutting and Vinyl Cutting
The laser-cut acrylic display component was updated in Day 2 and successfully integrated into the watch assembly. The acrylic display provides a clear protective face for the aging clock watch, precisely fitted to the casing dimensions.
The integrated watch assembly demonstrates successful integration of 2D subtractive manufacturing with 3D printed components, creating a cohesive mechanical structure for the wearable subsystem.
2.2 3D Printing: Rigid and Flexible Components
All 3D printed components were fabricated using both rigid and flexible materials. The bands were printed using TPU (Thermoplastic Polyurethane) for flexibility, while rigid components used standard PLA/PETG materials. Additional print details and configuration requirements are documented in Day 2.
The case should also be printed from TPU to improve interlock part fit. The spring-loaded interlock mechanism enables secure band closure while maintaining flexibility for comfortable wear.
TPU Band Print 1: Flexible wearable band component printed using TPU material for comfort and durability
TPU Band Print 2: Flexible band component demonstrating material properties and print quality
Band Closure: Interlock mechanism enabling secure band closure for wearable integration
Rigid Dock: 3D printed dock component for secure board mounting and electrical connection
Assembled Rigid Dock: Complete dock assembly showing board integration and mechanical mounting
Spring-Loaded Interlock: Detailed view of the interlock mechanism enabling secure yet flexible band closure
Spring-Loaded Interlock Operation: Demonstration of the interlock mechanism in action, showing secure closure and release functionality for the wearable band system.
2.3 Milling: Single and Double-Sided Boards
Aging Clock Watch Board
The aging clock watch board was successfully milled. The base design with OLED display worked correctly, and the design has been upgraded to include a TFT display. The new TFT-integrated design will be milled and tested alongside the base OLED version to validate both display options.
Milling Process 1: Initial milling operation for aging clock watch board
Tool Probing: Z-axis calibration and tool location setup for precise milling depth control
Milling Process 2: Continued milling operation showing tool path execution
Milling Process 3: Final milling passes completing board fabrication
Completed Milling: Finished aging clock board after successful milling operation
Vacuuming Debris: Post-milling cleanup process removing copper and substrate debris
Board Removal: Completed aging clock watch board removed from milling machine, ready for component soldering and testing.
MirrorAge Amplifier Board
The base MirrorAge amplifier board milling initially failed due to polygon pour isolation settings. The default isolation distance was set to 0 mil, which caused routing issues. After changing the back-side polygon pour isolation to 32 mil, the milling operation succeeded. When the shop closed, the design was upgraded to include a TFT screen. Both the base design and TFT-integrated versions will be milled together and tested.
Milling Process 1: Initial MirrorAge board milling operation
Milling Process 2: Continued milling showing tool path execution
Failed Milling: Initial milling failure caused by polygon pour isolation set to 0 mil
Failed Milling Video: Demonstration of milling failure due to incorrect isolation settings
Second-Side Fixturing: Board secured for double-sided milling operation
Second-Side Milling: Back-side milling operation for double-sided board
Back-Side Milling: Completing double-sided board fabrication
Fixed Isolation Setting: Polygon pour isolation corrected to 32 mil for proper routing
Successful Milling with Fixed Settings: MirrorAge board milling operation completing successfully after correcting polygon pour isolation to 32 mil, demonstrating the importance of proper PCB design rule configuration.
2.4 Integrating Fabrication
Physical integration of fabricated components demonstrates successful coordination between mechanical and electrical subsystems. The watch board fits within the watch case, and the acrylic display integrates properly. Additional work remains for drilling mounting holes for electronics and routing power connections.
Aging Clock Integration: Watch board and case integration showing proper dimensional fit
Integrated Watch Board: Complete watch board assembly within case, demonstrating successful mechanical integration
Assembled Bands: Complete band assembly with clip mechanism for secure attachment
Interlock Mechanism: Spring-loaded interlock providing secure yet flexible band closure
Interlock Operation: Demonstration of spring-loaded interlock mechanism enabling secure band closure and release for comfortable wearable integration.
TFT Display Upgrades
Both board designs have been upgraded to include TFT displays, and integration testing confirms proper fit. The TFT watch board fits correctly with the TFT display, and both the base and TFT-integrated MirrorAge load cell-speaker boards fit within the gripper enclosure. Additional work is needed for drilling mounting holes and adding hooks for load cell wire routing to the HX711 mounted on the board, as well as routing power connections.
Component soldering (pending board fit resolution)
Band mold printing and casting
3D printing of board cases (casing, dock, bands) ✓
2D subtractive: laser-cut acrylic display ✓
Mirror film application to screen
Phase 3: Integration & ProgrammingPENDING
Board-level firmware integration
WiFi network coordination between boards
Server-level code development
Serial communication: pulse oximeter to heart display (BPM/SpO2)
System wiring and wireless connection setup
Phase 4: Testing & DocumentationPENDING
Integrated system testing and validation
System evaluation and cost documentation
One-minute video production (conception, construction, operation)
Summary slide preparation
Final documentation review and completion
Current Status
✓
Completed:
Subsystem testing and validation, CAD model consolidation, demo table integration design, aging clock PCB design (accelerometer/camera + pulse oximeter), 3D printing of mechanical components (casing with organic support, dock with brim, TPU bands), laser-cut acrylic display, initial board milling
→
In Progress:
Board fit optimization (casing adjustment vs. miniaturized board), MirrorAge board design (handgrip + speaker + TFT), data integration methods documentation (serial, WiFi, MQTT spiral development)
○
Upcoming:
Component soldering, band mold printing and casting, firmware integration, WiFi/MQTT network setup, system wiring, integrated testing, final documentation
Buffer Days (Saturday & Sunday)
Tasks that cannot be completed during scheduled weekdays will be shifted to Saturday and Sunday buffer days. This ensures the critical path remains on schedule while allowing flexibility for unexpected delays or additional refinement work.
Data Integration Methods to Spirally Develop
Progressive development approach for integrating sensor data streams from multiple subsystems, starting with simple serial communication and evolving to wireless network-based architectures.
Method 1: Serial Communication (Easiest)
Direct serial communication through USB cable from computer to microcontroller, using PySerial to stream data. This provides the simplest initial integration path for rapid prototyping and debugging.
Implementation:
USB cable connection from computer to ESP32-S3 microcontroller
PySerial library for Python-based data streaming
Arduino Serial functions for microcontroller-side communication
Configure all microcontrollers as WiFi clients that stream data to a flash web server. This enables wireless communication while maintaining a centralized data aggregation point.
Implementation:
All ESP32-S3 boards configured as WiFi clients on the same network
Central web server (initially laptop-hosted) receives data streams
WiFiClient::write() functions for data transmission
Message Queuing Telemetry Transport (MQTT) provides a lightweight, publish-subscribe messaging protocol ideal for IoT device communication. This approach enables decentralized data exchange between all MirrorAge subsystems, allowing each board to publish sensor data and subscribe to relevant topics for coordinated system behavior.
Server Hosting Strategy:
Initial development and testing will use a laptop-hosted MQTT broker. In a later development spiral, the server will be migrated to a dedicated Raspberry Pi Zero or Raspberry Pi 5 for standalone operation and improved system portability. Paho MQTT library has been successfully tested for ESP32-S3 implementation.
Development will progress through these methods in order of complexity, starting with serial communication for rapid prototyping, then moving to WiFi client architecture for wireless operation, and finally implementing MQTT for advanced decentralized communication. Each subsystem board (pulse oximeter, OLED/accelerometer, speaker/amplifier, load cell) will be integrated progressively, enabling:
Incremental complexity management and early validation
Decoupled communication between subsystems
Real-time data streaming from multiple sensors
Scalable architecture for adding new sensor modules
Flexible server deployment (laptop → Raspberry Pi migration path)
Reflections & Learnings
Reflections and key learnings from the final project integration week.
Key Points
System integration requires careful coordination of mechanical, electrical, and software subsystems
Comprehensive planning and day-by-day scheduling are essential for managing complex integration tasks
Modular design enables incremental testing and validation of individual components before full system assembly
Documentation throughout the integration process supports debugging and future improvements
Final integration week demands focus, organization, and the ability to adapt to unexpected challenges
Contributions
Acknowledgments for contributions and collaborations during the final project week.
Ethical AI Use
Documentation of AI-assisted tasks and tools used during the final project integration week.
📋 General Guidelines: See General Commands for Cursor on the homepage for standard guidelines and commands used consistently throughout documentation development.
Cursor · Project Plan & Weekly Schedule
Comprehensive Cursor AI assistance for outlining the project plan and weekly schedule, including documentation structure, content organization, systematic updates across all week pages and the final project page, media integration, and summary generation workflows.
Cursor AI assistance for Week 14 project integration updates, including Day 2 electrical and mechanical integration documentation, data integration methods refinement, and critical path analysis updates.
Final project integration week focused on bringing together all subsystems into a cohesive MirrorAge system, completing documentation, and preparing for final presentation.
Final integration week focused on bringing all subsystems together, completing hardware fabrication, firmware integration, and documentation for the MirrorAge system presentation.
The act of bringing something to a conclusion or ending in a decisive manner. The ability to efficiently finish tasks and projects with a goal-oriented mindset.
Wednesday
Morning
Publish system integration plan on website
Update weekly assignment sections on final project page (weeks 10-13)
Link final project design files
Update reflections and learnings
Update picture of prism holder
Add final pictures to Slack canvases
Create schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Start CAD model of system
Place final order
Afternoon & Evening
Design:
Boards: Combine OLED screen/accelerometer with pulse oximeter board in a new board (maybe upgrade to small TFT as minor)
Boards: Speaker board with realtime amplifier and TFT (on the load cell fixed board)
Band: Mold design
Cases: 3D print mountable cases for the boards
Integrate designs into final CAD
Document design
Finish CAD model of system
Thursday
Fabricate
Milling boards
Print mold and cast band
Print cases
Solder
Solder components on milled boards
Connect boards with wired (and wireless connection codes)
Finishing
Mirror on screen (easy way with the film)
Documentation
Document fabrication
Friday
Programming
Board level codes
Server level codes
Documentation
Document codes
Completion
Finish anything else
Saturday
Programming & Testing
Demo integrated system
Test integrated system
Documentation
Document testing and evaluation
Review and complete documentation (list of questions)
Make the video by collaging documentation
Sunday
Fill up any gaps
Prepare demo on tensegrity table
Finalize 1-slide
Work on minors
If done, work on if there's time
Monday Morning
Transport demo on tensegrity table
Fill up any gaps
Work on minors
Specific Tasks to Complete This Week
Major Tasks
CAD model of system
Speaker board with realtime amplifier
Combine screen/accelerometer with pulse oximeter board in a new board
Mold and cast band
Design and fabricate casing (print)
Schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Serial connection between pulse oximeter and tiny blinking heart for BPM (BPM from IR, SpO2 from delta)
Combine multiple boards on the same WiFi (switching tabs is easy way, board hosting the webpage querying and update or Python-based server somewhere where everything posting data, Raspberry Pi)
Put+program everything together according to the above (with WiFi for now)
Summary slide and one-minute video for documentation
Conception
Construction
Operation
Minor Tasks
Program microphone/speaker
Fix reaction time delay code
Program LoRa connection
Fix OLED plus WiFi issue
Upgrade to TFT (SPI is very straightforward, design board with either SPI or OLED connection)
Fix heart engraving to center
Engrave K9 glass mirror if it arrives
RD and IRD isolation slit (maybe wick and then cut)
Do the calibration curve for the load cell
Finish cardboard laser cutter origami big mirror frame
If There's Time
Moving base of mirror
Orders
Raspberry Pi Zero (or server host, do some research)
Presentation
Aim for 2.5 minutes because Neil will ask questions
Generally no slides except for 1 open summary slide (have backup slides in case questions come up!)
Related: See the Development Timeline on the final project page for the overall project schedule.
Day 1: Design Integration
Initial system integration work focused on subsystem validation, CAD model consolidation, and design backbone acquisition for band integration.
Subsystem Validation
Conducted comprehensive testing of all subsystems to ensure proper functionality. Identified and resoldered any defective joints, verifying that each subsystem operates correctly before proceeding with full system integration.
CAD Model Consolidation
Exported CAD models of all PCBs in the final design and imported them into a unified CAD assembly. This consolidated model provides a complete view of the system's mechanical integration and spatial relationships.
Integrated CAD Model: Exploded isometric view of the complete system assembly, including all PCBs (pulse oximeter, OLED/accelerometer, speaker/amplifier), main housing with transparent enclosure, and wearable band components. The model shows the spatial relationships between electronic subsystems and mechanical structures, enabling precise integration planning.
Band Design Backbone
Acquired CAD design files for Apple Watch form factor integration, enabling compatibility with existing band designs and standardized watch components. This provides a proven mechanical foundation for the wearable subsystem.
Resuming the daily schedule tomorrow with parallel work streams prioritized according to the critical path. Tasks that cannot be completed during scheduled days will be shifted to buffer days on Saturday and Sunday to maintain project momentum.
Day 2: Electrical and Mechanical Integration
Physical integration of subsystems into the complete demo table assembly, including mechanical component fabrication and electrical board consolidation.
2.1 Mechanical Integration
Mechanical design integration now includes the complete demo table with precise placement of the MirrorAge handgrip subsystem and the aging clock subsystem. The integrated assembly provides a unified platform for system demonstration and testing.
Complete Demo Table Assembly: Integrated mechanical design showing precise placement of the MirrorAge handgrip subsystem and aging clock subsystem on the demo table. The assembly demonstrates the spatial relationships and mounting configurations for both subsystems within the unified demonstration platform.
3D Additive Manufacturing
All 3D additive mechanical components were printed for rapid iterative development. The fabrication process required specific print settings and support strategies for different components:
Printing Initiation: 3D printer starting the fabrication process for mechanical components
Casing Print: Casing component during 3D printing process
Print Configuration Requirements:
Casing: Required organic support structures for complex overhangs
Dock: Required brim adhesion to prevent warping during printing
Bands: Printed using TPU (Thermoplastic Polyurethane) material for flexibility (will spiral into molding and casting in future iterations)
Organic Support Configuration: Slicer settings showing organic support structures for the casing component
Brim Addition: Dock component with brim added to prevent warping during printing
Casing with Organic Support: Printed casing component showing organic support structures
TPU Bands: Flexible wearable band components printed using TPU material
Print Failures and Iteration
Failed Casing Print: Initial casing print failure requiring support structure adjustments
Failed Dock Print: Dock print failure due to warping, resolved with brim addition
Printing Failures: Documentation of various print failures encountered during iterative development
Printing Progress: Successful components showing iterative improvement in print quality
2D Subtractive Manufacturing
The first 2D subtractive mechanical component was debugged and fabricated. The display face component required exporting a DXF of the full face to laser cut an acrylic display that fits the casing precisely. The original display part face was too small because it was filleted, so the edges of the aging clock body were traced and exported for accurate laser cutting.
Laser Cutting Process 1: Initial laser cutting of acrylic display component
Laser Cutting Process 2: Continued laser cutting operation for display face
Acrylic Display Fit: Laser-cut acrylic display component precisely fitted into the casing, demonstrating successful integration of 2D subtractive and 3D additive manufacturing components.
2.2 Electrical Integration
Electrical design integration now combines the accelerometer/camera board with the pulse oximeter board into a single unified design that fits inside the casing. The integrated board may be upgraded to include a small TFT screen in a future iteration if space constraints allow.
Board Design Evolution
Initial Board Design: First integrated board design showing size constraints relative to casing dimensions
Board in Casing: Revised board design fitted within casing dimensional constraints
Final Integrated Board Design: Complete aging clock board design combining accelerometer/camera functionality with pulse oximeter sensors in a single unified PCB layout optimized for casing fit and component placement.
TFT Display Integration
Both the aging clock watch board and the MirrorAge load cell-speaker board have been upgraded to include TFT displays for enhanced visual feedback. The displays use SPI communication for straightforward integration with the ESP32-S3 XIAO microcontroller.
TFT Display Wiring: Pin connection diagram showing SPI interface connections between TFT displays and ESP32-S3 XIAO microcontroller for both watch and MirrorAge boards.
MirrorAge Amplifier Board Design
The MirrorAge amplifier board integrates a real-time audio amplifier with load cell interface and TFT display. The base design includes the amplifier circuit and HX711 load cell interface, with an upgraded version adding the 2.4" ILI9341 TFT display.
Base Amplifier Board: Initial design with real-time amplifier and HX711 load cell interface
Base Board Layout: PCB layout showing component placement for amplifier and load cell interface
TFT Display Component:
1.8" TFT LCD: ST7735 controller, 128×160 pixels. CAD model reference:
GrabCAD ST7735 Model
TFT-Integrated MirrorAge Board: Upgraded PCB design incorporating the 2.4" ILI9341 TFT display alongside the amplifier and load cell interface, enabling visual feedback for grip strength measurements.
Aging Clock Watch Board Design
The aging clock watch board combines pulse oximeter sensors, accelerometer, and camera functionality. The base design uses an OLED display, with an upgraded version incorporating a 1.8" ST7735 TFT display for enhanced visual feedback.
Base Aging Clock Board: Initial design integrating pulse oximeter, accelerometer, and camera with OLED display for wearable watch form factor.
Board Fabrication and Integration
The first version of the aging clock board was milled. The initial board did not fit the casing, requiring either casing adjustment and reprinting, or milling a new miniaturized board with shrunken electronics. Both approaches are being evaluated. The MirrorAge board design has been completed for both base and TFT-integrated versions, ready for milling and testing.
Milled Integrated Board: First version of the integrated aging clock board after PCB milling, showing component placement and routing
Board Fit Test: Milled board nearly fitting in casing, demonstrating the need for dimensional optimization
Board Deflection Fixing: Process of addressing board deflection and mechanical fit issues during integration testing, demonstrating iterative refinement of the electrical-mechanical interface.
Day 3: Fabrication Integration
Comprehensive fabrication integration work combining 2D laser cutting, 3D printing, and PCB milling to create fully integrated subsystems ready for assembly and testing.
2.1 2D Fabrication: Laser Cutting and Vinyl Cutting
The laser-cut acrylic display component was updated in Day 2 and successfully integrated into the watch assembly. The acrylic display provides a clear protective face for the aging clock watch, precisely fitted to the casing dimensions.
The integrated watch assembly demonstrates successful integration of 2D subtractive manufacturing with 3D printed components, creating a cohesive mechanical structure for the wearable subsystem.
2.2 3D Printing: Rigid and Flexible Components
All 3D printed components were fabricated using both rigid and flexible materials. The bands were printed using TPU (Thermoplastic Polyurethane) for flexibility, while rigid components used standard PLA/PETG materials. Additional print details and configuration requirements are documented in Day 2.
The case should also be printed from TPU to improve interlock part fit. The spring-loaded interlock mechanism enables secure band closure while maintaining flexibility for comfortable wear.
TPU Band Print 1: Flexible wearable band component printed using TPU material for comfort and durability
TPU Band Print 2: Flexible band component demonstrating material properties and print quality
Band Closure: Interlock mechanism enabling secure band closure for wearable integration
Rigid Dock: 3D printed dock component for secure board mounting and electrical connection
Assembled Rigid Dock: Complete dock assembly showing board integration and mechanical mounting
Spring-Loaded Interlock: Detailed view of the interlock mechanism enabling secure yet flexible band closure
Spring-Loaded Interlock Operation: Demonstration of the interlock mechanism in action, showing secure closure and release functionality for the wearable band system.
2.3 Milling: Single and Double-Sided Boards
Aging Clock Watch Board
The aging clock watch board was successfully milled. The base design with OLED display worked correctly, and the design has been upgraded to include a TFT display. The new TFT-integrated design will be milled and tested alongside the base OLED version to validate both display options.
Milling Process 1: Initial milling operation for aging clock watch board
Tool Probing: Z-axis calibration and tool location setup for precise milling depth control
Milling Process 2: Continued milling operation showing tool path execution
Milling Process 3: Final milling passes completing board fabrication
Completed Milling: Finished aging clock board after successful milling operation
Vacuuming Debris: Post-milling cleanup process removing copper and substrate debris
Board Removal: Completed aging clock watch board removed from milling machine, ready for component soldering and testing.
MirrorAge Amplifier Board
The base MirrorAge amplifier board milling initially failed due to polygon pour isolation settings. The default isolation distance was set to 0 mil, which caused routing issues. After changing the back-side polygon pour isolation to 32 mil, the milling operation succeeded. When the shop closed, the design was upgraded to include a TFT screen. Both the base design and TFT-integrated versions will be milled together and tested.
Milling Process 1: Initial MirrorAge board milling operation
Milling Process 2: Continued milling showing tool path execution
Failed Milling: Initial milling failure caused by polygon pour isolation set to 0 mil
Failed Milling Video: Demonstration of milling failure due to incorrect isolation settings
Second-Side Fixturing: Board secured for double-sided milling operation
Second-Side Milling: Back-side milling operation for double-sided board
Back-Side Milling: Completing double-sided board fabrication
Fixed Isolation Setting: Polygon pour isolation corrected to 32 mil for proper routing
Successful Milling with Fixed Settings: MirrorAge board milling operation completing successfully after correcting polygon pour isolation to 32 mil, demonstrating the importance of proper PCB design rule configuration.
2.4 Integrating Fabrication
Physical integration of fabricated components demonstrates successful coordination between mechanical and electrical subsystems. The watch board fits within the watch case, and the acrylic display integrates properly. Additional work remains for drilling mounting holes for electronics and routing power connections.
Aging Clock Integration: Watch board and case integration showing proper dimensional fit
Integrated Watch Board: Complete watch board assembly within case, demonstrating successful mechanical integration
Assembled Bands: Complete band assembly with clip mechanism for secure attachment
Interlock Mechanism: Spring-loaded interlock providing secure yet flexible band closure
Interlock Operation: Demonstration of spring-loaded interlock mechanism enabling secure band closure and release for comfortable wearable integration.
TFT Display Upgrades
Both board designs have been upgraded to include TFT displays, and integration testing confirms proper fit. The TFT watch board fits correctly with the TFT display, and both the base and TFT-integrated MirrorAge load cell-speaker boards fit within the gripper enclosure. Additional work is needed for drilling mounting holes and adding hooks for load cell wire routing to the HX711 mounted on the board, as well as routing power connections.
Component soldering (pending board fit resolution)
Band mold printing and casting
3D printing of board cases (casing, dock, bands) ✓
2D subtractive: laser-cut acrylic display ✓
Mirror film application to screen
Phase 3: Integration & ProgrammingPENDING
Board-level firmware integration
WiFi network coordination between boards
Server-level code development
Serial communication: pulse oximeter to heart display (BPM/SpO2)
System wiring and wireless connection setup
Phase 4: Testing & DocumentationPENDING
Integrated system testing and validation
System evaluation and cost documentation
One-minute video production (conception, construction, operation)
Summary slide preparation
Final documentation review and completion
Current Status
✓
Completed:
Subsystem testing and validation, CAD model consolidation, demo table integration design, aging clock PCB design (accelerometer/camera + pulse oximeter), 3D printing of mechanical components (casing with organic support, dock with brim, TPU bands), laser-cut acrylic display, initial board milling
→
In Progress:
Board fit optimization (casing adjustment vs. miniaturized board), MirrorAge board design (handgrip + speaker + TFT), data integration methods documentation (serial, WiFi, MQTT spiral development)
○
Upcoming:
Component soldering, band mold printing and casting, firmware integration, WiFi/MQTT network setup, system wiring, integrated testing, final documentation
Buffer Days (Saturday & Sunday)
Tasks that cannot be completed during scheduled weekdays will be shifted to Saturday and Sunday buffer days. This ensures the critical path remains on schedule while allowing flexibility for unexpected delays or additional refinement work.
Data Integration Methods to Spirally Develop
Progressive development approach for integrating sensor data streams from multiple subsystems, starting with simple serial communication and evolving to wireless network-based architectures.
Method 1: Serial Communication (Easiest)
Direct serial communication through USB cable from computer to microcontroller, using PySerial to stream data. This provides the simplest initial integration path for rapid prototyping and debugging.
Implementation:
USB cable connection from computer to ESP32-S3 microcontroller
PySerial library for Python-based data streaming
Arduino Serial functions for microcontroller-side communication
Configure all microcontrollers as WiFi clients that stream data to a flash web server. This enables wireless communication while maintaining a centralized data aggregation point.
Implementation:
All ESP32-S3 boards configured as WiFi clients on the same network
Central web server (initially laptop-hosted) receives data streams
WiFiClient::write() functions for data transmission
Message Queuing Telemetry Transport (MQTT) provides a lightweight, publish-subscribe messaging protocol ideal for IoT device communication. This approach enables decentralized data exchange between all MirrorAge subsystems, allowing each board to publish sensor data and subscribe to relevant topics for coordinated system behavior.
Server Hosting Strategy:
Initial development and testing will use a laptop-hosted MQTT broker. In a later development spiral, the server will be migrated to a dedicated Raspberry Pi Zero or Raspberry Pi 5 for standalone operation and improved system portability. Paho MQTT library has been successfully tested for ESP32-S3 implementation.
Development will progress through these methods in order of complexity, starting with serial communication for rapid prototyping, then moving to WiFi client architecture for wireless operation, and finally implementing MQTT for advanced decentralized communication. Each subsystem board (pulse oximeter, OLED/accelerometer, speaker/amplifier, load cell) will be integrated progressively, enabling:
Incremental complexity management and early validation
Decoupled communication between subsystems
Real-time data streaming from multiple sensors
Scalable architecture for adding new sensor modules
Flexible server deployment (laptop → Raspberry Pi migration path)
Reflections & Learnings
Reflections and key learnings from the final project integration week.
Key Points
System integration requires careful coordination of mechanical, electrical, and software subsystems
Comprehensive planning and day-by-day scheduling are essential for managing complex integration tasks
Modular design enables incremental testing and validation of individual components before full system assembly
Documentation throughout the integration process supports debugging and future improvements
Final integration week demands focus, organization, and the ability to adapt to unexpected challenges
Contributions
Acknowledgments for contributions and collaborations during the final project week.
Ethical AI Use
Documentation of AI-assisted tasks and tools used during the final project integration week.
📋 General Guidelines: See General Commands for Cursor on the homepage for standard guidelines and commands used consistently throughout documentation development.
Cursor · Project Plan & Weekly Schedule
Comprehensive Cursor AI assistance for outlining the project plan and weekly schedule, including documentation structure, content organization, systematic updates across all week pages and the final project page, media integration, and summary generation workflows.
Cursor AI assistance for Week 14 project integration updates, including Day 2 electrical and mechanical integration documentation, data integration methods refinement, and critical path analysis updates.
Final project integration week focused on bringing together all subsystems into a cohesive MirrorAge system, completing documentation, and preparing for final presentation.
Final integration week focused on bringing all subsystems together, completing hardware fabrication, firmware integration, and documentation for the MirrorAge system presentation.
The act of bringing something to a conclusion or ending in a decisive manner. The ability to efficiently finish tasks and projects with a goal-oriented mindset.
Wednesday
Morning
Publish system integration plan on website
Update weekly assignment sections on final project page (weeks 10-13)
Link final project design files
Update reflections and learnings
Update picture of prism holder
Add final pictures to Slack canvases
Create schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Start CAD model of system
Place final order
Afternoon & Evening
Design:
Boards: Combine OLED screen/accelerometer with pulse oximeter board in a new board (maybe upgrade to small TFT as minor)
Boards: Speaker board with realtime amplifier and TFT (on the load cell fixed board)
Band: Mold design
Cases: 3D print mountable cases for the boards
Integrate designs into final CAD
Document design
Finish CAD model of system
Thursday
Fabricate
Milling boards
Print mold and cast band
Print cases
Solder
Solder components on milled boards
Connect boards with wired (and wireless connection codes)
Finishing
Mirror on screen (easy way with the film)
Documentation
Document fabrication
Friday
Programming
Board level codes
Server level codes
Documentation
Document codes
Completion
Finish anything else
Saturday
Programming & Testing
Demo integrated system
Test integrated system
Documentation
Document testing and evaluation
Review and complete documentation (list of questions)
Make the video by collaging documentation
Sunday
Fill up any gaps
Prepare demo on tensegrity table
Finalize 1-slide
Work on minors
If done, work on if there's time
Monday Morning
Transport demo on tensegrity table
Fill up any gaps
Work on minors
Specific Tasks to Complete This Week
Major Tasks
CAD model of system
Speaker board with realtime amplifier
Combine screen/accelerometer with pulse oximeter board in a new board
Mold and cast band
Design and fabricate casing (print)
Schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Serial connection between pulse oximeter and tiny blinking heart for BPM (BPM from IR, SpO2 from delta)
Combine multiple boards on the same WiFi (switching tabs is easy way, board hosting the webpage querying and update or Python-based server somewhere where everything posting data, Raspberry Pi)
Put+program everything together according to the above (with WiFi for now)
Summary slide and one-minute video for documentation
Conception
Construction
Operation
Minor Tasks
Program microphone/speaker
Fix reaction time delay code
Program LoRa connection
Fix OLED plus WiFi issue
Upgrade to TFT (SPI is very straightforward, design board with either SPI or OLED connection)
Fix heart engraving to center
Engrave K9 glass mirror if it arrives
RD and IRD isolation slit (maybe wick and then cut)
Do the calibration curve for the load cell
Finish cardboard laser cutter origami big mirror frame
If There's Time
Moving base of mirror
Orders
Raspberry Pi Zero (or server host, do some research)
Presentation
Aim for 2.5 minutes because Neil will ask questions
Generally no slides except for 1 open summary slide (have backup slides in case questions come up!)
Related: See the Development Timeline on the final project page for the overall project schedule.
Day 1: Design Integration
Initial system integration work focused on subsystem validation, CAD model consolidation, and design backbone acquisition for band integration.
Subsystem Validation
Conducted comprehensive testing of all subsystems to ensure proper functionality. Identified and resoldered any defective joints, verifying that each subsystem operates correctly before proceeding with full system integration.
CAD Model Consolidation
Exported CAD models of all PCBs in the final design and imported them into a unified CAD assembly. This consolidated model provides a complete view of the system's mechanical integration and spatial relationships.
Integrated CAD Model: Exploded isometric view of the complete system assembly, including all PCBs (pulse oximeter, OLED/accelerometer, speaker/amplifier), main housing with transparent enclosure, and wearable band components. The model shows the spatial relationships between electronic subsystems and mechanical structures, enabling precise integration planning.
Band Design Backbone
Acquired CAD design files for Apple Watch form factor integration, enabling compatibility with existing band designs and standardized watch components. This provides a proven mechanical foundation for the wearable subsystem.
Resuming the daily schedule tomorrow with parallel work streams prioritized according to the critical path. Tasks that cannot be completed during scheduled days will be shifted to buffer days on Saturday and Sunday to maintain project momentum.
Day 2: Electrical and Mechanical Integration
Physical integration of subsystems into the complete demo table assembly, including mechanical component fabrication and electrical board consolidation.
2.1 Mechanical Integration
Mechanical design integration now includes the complete demo table with precise placement of the MirrorAge handgrip subsystem and the aging clock subsystem. The integrated assembly provides a unified platform for system demonstration and testing.
Complete Demo Table Assembly: Integrated mechanical design showing precise placement of the MirrorAge handgrip subsystem and aging clock subsystem on the demo table. The assembly demonstrates the spatial relationships and mounting configurations for both subsystems within the unified demonstration platform.
3D Additive Manufacturing
All 3D additive mechanical components were printed for rapid iterative development. The fabrication process required specific print settings and support strategies for different components:
Printing Initiation: 3D printer starting the fabrication process for mechanical components
Casing Print: Casing component during 3D printing process
Print Configuration Requirements:
Casing: Required organic support structures for complex overhangs
Dock: Required brim adhesion to prevent warping during printing
Bands: Printed using TPU (Thermoplastic Polyurethane) material for flexibility (will spiral into molding and casting in future iterations)
Organic Support Configuration: Slicer settings showing organic support structures for the casing component
Brim Addition: Dock component with brim added to prevent warping during printing
Casing with Organic Support: Printed casing component showing organic support structures
TPU Bands: Flexible wearable band components printed using TPU material
Print Failures and Iteration
Failed Casing Print: Initial casing print failure requiring support structure adjustments
Failed Dock Print: Dock print failure due to warping, resolved with brim addition
Printing Failures: Documentation of various print failures encountered during iterative development
Printing Progress: Successful components showing iterative improvement in print quality
2D Subtractive Manufacturing
The first 2D subtractive mechanical component was debugged and fabricated. The display face component required exporting a DXF of the full face to laser cut an acrylic display that fits the casing precisely. The original display part face was too small because it was filleted, so the edges of the aging clock body were traced and exported for accurate laser cutting.
Laser Cutting Process 1: Initial laser cutting of acrylic display component
Laser Cutting Process 2: Continued laser cutting operation for display face
Acrylic Display Fit: Laser-cut acrylic display component precisely fitted into the casing, demonstrating successful integration of 2D subtractive and 3D additive manufacturing components.
2.2 Electrical Integration
Electrical design integration now combines the accelerometer/camera board with the pulse oximeter board into a single unified design that fits inside the casing. The integrated board may be upgraded to include a small TFT screen in a future iteration if space constraints allow.
Board Design Evolution
Initial Board Design: First integrated board design showing size constraints relative to casing dimensions
Board in Casing: Revised board design fitted within casing dimensional constraints
Final Integrated Board Design: Complete aging clock board design combining accelerometer/camera functionality with pulse oximeter sensors in a single unified PCB layout optimized for casing fit and component placement.
TFT Display Integration
Both the aging clock watch board and the MirrorAge load cell-speaker board have been upgraded to include TFT displays for enhanced visual feedback. The displays use SPI communication for straightforward integration with the ESP32-S3 XIAO microcontroller.
TFT Display Wiring: Pin connection diagram showing SPI interface connections between TFT displays and ESP32-S3 XIAO microcontroller for both watch and MirrorAge boards.
MirrorAge Amplifier Board Design
The MirrorAge amplifier board integrates a real-time audio amplifier with load cell interface and TFT display. The base design includes the amplifier circuit and HX711 load cell interface, with an upgraded version adding the 2.4" ILI9341 TFT display.
Base Amplifier Board: Initial design with real-time amplifier and HX711 load cell interface
Base Board Layout: PCB layout showing component placement for amplifier and load cell interface
TFT Display Component:
1.8" TFT LCD: ST7735 controller, 128×160 pixels. CAD model reference:
GrabCAD ST7735 Model
TFT-Integrated MirrorAge Board: Upgraded PCB design incorporating the 2.4" ILI9341 TFT display alongside the amplifier and load cell interface, enabling visual feedback for grip strength measurements.
Aging Clock Watch Board Design
The aging clock watch board combines pulse oximeter sensors, accelerometer, and camera functionality. The base design uses an OLED display, with an upgraded version incorporating a 1.8" ST7735 TFT display for enhanced visual feedback.
Base Aging Clock Board: Initial design integrating pulse oximeter, accelerometer, and camera with OLED display for wearable watch form factor.
Board Fabrication and Integration
The first version of the aging clock board was milled. The initial board did not fit the casing, requiring either casing adjustment and reprinting, or milling a new miniaturized board with shrunken electronics. Both approaches are being evaluated. The MirrorAge board design has been completed for both base and TFT-integrated versions, ready for milling and testing.
Milled Integrated Board: First version of the integrated aging clock board after PCB milling, showing component placement and routing
Board Fit Test: Milled board nearly fitting in casing, demonstrating the need for dimensional optimization
Board Deflection Fixing: Process of addressing board deflection and mechanical fit issues during integration testing, demonstrating iterative refinement of the electrical-mechanical interface.
Day 3: Fabrication Integration
Comprehensive fabrication integration work combining 2D laser cutting, 3D printing, and PCB milling to create fully integrated subsystems ready for assembly and testing.
2.1 2D Fabrication: Laser Cutting and Vinyl Cutting
The laser-cut acrylic display component was updated in Day 2 and successfully integrated into the watch assembly. The acrylic display provides a clear protective face for the aging clock watch, precisely fitted to the casing dimensions.
The integrated watch assembly demonstrates successful integration of 2D subtractive manufacturing with 3D printed components, creating a cohesive mechanical structure for the wearable subsystem.
2.2 3D Printing: Rigid and Flexible Components
All 3D printed components were fabricated using both rigid and flexible materials. The bands were printed using TPU (Thermoplastic Polyurethane) for flexibility, while rigid components used standard PLA/PETG materials. Additional print details and configuration requirements are documented in Day 2.
The case should also be printed from TPU to improve interlock part fit. The spring-loaded interlock mechanism enables secure band closure while maintaining flexibility for comfortable wear.
TPU Band Print 1: Flexible wearable band component printed using TPU material for comfort and durability
TPU Band Print 2: Flexible band component demonstrating material properties and print quality
Band Closure: Interlock mechanism enabling secure band closure for wearable integration
Rigid Dock: 3D printed dock component for secure board mounting and electrical connection
Assembled Rigid Dock: Complete dock assembly showing board integration and mechanical mounting
Spring-Loaded Interlock: Detailed view of the interlock mechanism enabling secure yet flexible band closure
Spring-Loaded Interlock Operation: Demonstration of the interlock mechanism in action, showing secure closure and release functionality for the wearable band system.
2.3 Milling: Single and Double-Sided Boards
Aging Clock Watch Board
The aging clock watch board was successfully milled. The base design with OLED display worked correctly, and the design has been upgraded to include a TFT display. The new TFT-integrated design will be milled and tested alongside the base OLED version to validate both display options.
Milling Process 1: Initial milling operation for aging clock watch board
Tool Probing: Z-axis calibration and tool location setup for precise milling depth control
Milling Process 2: Continued milling operation showing tool path execution
Milling Process 3: Final milling passes completing board fabrication
Completed Milling: Finished aging clock board after successful milling operation
Vacuuming Debris: Post-milling cleanup process removing copper and substrate debris
Board Removal: Completed aging clock watch board removed from milling machine, ready for component soldering and testing.
MirrorAge Amplifier Board
The base MirrorAge amplifier board milling initially failed due to polygon pour isolation settings. The default isolation distance was set to 0 mil, which caused routing issues. After changing the back-side polygon pour isolation to 32 mil, the milling operation succeeded. When the shop closed, the design was upgraded to include a TFT screen. Both the base design and TFT-integrated versions will be milled together and tested.
Milling Process 1: Initial MirrorAge board milling operation
Milling Process 2: Continued milling showing tool path execution
Failed Milling: Initial milling failure caused by polygon pour isolation set to 0 mil
Failed Milling Video: Demonstration of milling failure due to incorrect isolation settings
Second-Side Fixturing: Board secured for double-sided milling operation
Second-Side Milling: Back-side milling operation for double-sided board
Back-Side Milling: Completing double-sided board fabrication
Fixed Isolation Setting: Polygon pour isolation corrected to 32 mil for proper routing
Successful Milling with Fixed Settings: MirrorAge board milling operation completing successfully after correcting polygon pour isolation to 32 mil, demonstrating the importance of proper PCB design rule configuration.
2.4 Integrating Fabrication
Physical integration of fabricated components demonstrates successful coordination between mechanical and electrical subsystems. The watch board fits within the watch case, and the acrylic display integrates properly. Additional work remains for drilling mounting holes for electronics and routing power connections.
Aging Clock Integration: Watch board and case integration showing proper dimensional fit
Integrated Watch Board: Complete watch board assembly within case, demonstrating successful mechanical integration
Assembled Bands: Complete band assembly with clip mechanism for secure attachment
Interlock Mechanism: Spring-loaded interlock providing secure yet flexible band closure
Interlock Operation: Demonstration of spring-loaded interlock mechanism enabling secure band closure and release for comfortable wearable integration.
TFT Display Upgrades
Both board designs have been upgraded to include TFT displays, and integration testing confirms proper fit. The TFT watch board fits correctly with the TFT display, and both the base and TFT-integrated MirrorAge load cell-speaker boards fit within the gripper enclosure. Additional work is needed for drilling mounting holes and adding hooks for load cell wire routing to the HX711 mounted on the board, as well as routing power connections.
3D printing of board cases (casing, dock, bands) ✓
2D subtractive: laser-cut acrylic display ✓
Physical integration: drilling mounting holes, routing power connections
Mirror film application to screen
Phase 3: Integration & ProgrammingPENDING
Board-level firmware integration
WiFi network coordination between boards
Server-level code development
Serial communication: pulse oximeter to heart display (BPM/SpO2)
System wiring and wireless connection setup
Phase 4: Testing & DocumentationPENDING
Integrated system testing and validation
System evaluation and cost documentation
One-minute video production (conception, construction, operation)
Summary slide preparation
Final documentation review and completion
Current Status
✓
Completed:
Subsystem testing and validation, CAD model consolidation, demo table integration design, aging clock PCB design (accelerometer/camera + pulse oximeter), 3D printing of mechanical components (casing with organic support, dock with brim, TPU bands), laser-cut acrylic display, initial board milling
→
In Progress:
Board fit optimization (casing adjustment vs. miniaturized board), MirrorAge board design (handgrip + speaker + TFT), data integration methods documentation (serial, WiFi, MQTT spiral development)
○
Upcoming:
Component soldering, band mold printing and casting, firmware integration, WiFi/MQTT network setup, system wiring, integrated testing, final documentation
Buffer Days (Saturday & Sunday)
Tasks that cannot be completed during scheduled weekdays will be shifted to Saturday and Sunday buffer days. This ensures the critical path remains on schedule while allowing flexibility for unexpected delays or additional refinement work.
Data Integration Methods to Spirally Develop
Progressive development approach for integrating sensor data streams from multiple subsystems, starting with simple serial communication and evolving to wireless network-based architectures.
Method 1: Serial Communication (Easiest)
Direct serial communication through USB cable from computer to microcontroller, using PySerial to stream data. This provides the simplest initial integration path for rapid prototyping and debugging.
Implementation:
USB cable connection from computer to ESP32-S3 microcontroller
PySerial library for Python-based data streaming
Arduino Serial functions for microcontroller-side communication
Configure all microcontrollers as WiFi clients that stream data to a flash web server. This enables wireless communication while maintaining a centralized data aggregation point.
Implementation:
All ESP32-S3 boards configured as WiFi clients on the same network
Central web server (initially laptop-hosted) receives data streams
WiFiClient::write() functions for data transmission
Message Queuing Telemetry Transport (MQTT) provides a lightweight, publish-subscribe messaging protocol ideal for IoT device communication. This approach enables decentralized data exchange between all MirrorAge subsystems, allowing each board to publish sensor data and subscribe to relevant topics for coordinated system behavior.
Server Hosting Strategy:
Initial development and testing will use a laptop-hosted MQTT broker. In a later development spiral, the server will be migrated to a dedicated Raspberry Pi Zero or Raspberry Pi 5 for standalone operation and improved system portability. Paho MQTT library has been successfully tested for ESP32-S3 implementation.
Development will progress through these methods in order of complexity, starting with serial communication for rapid prototyping, then moving to WiFi client architecture for wireless operation, and finally implementing MQTT for advanced decentralized communication. Each subsystem board (pulse oximeter, OLED/accelerometer, speaker/amplifier, load cell) will be integrated progressively, enabling:
Incremental complexity management and early validation
Decoupled communication between subsystems
Real-time data streaming from multiple sensors
Scalable architecture for adding new sensor modules
Flexible server deployment (laptop → Raspberry Pi migration path)
Reflections & Learnings
Reflections and key learnings from the final project integration week.
Key Points
System integration requires careful coordination of mechanical, electrical, and software subsystems
Comprehensive planning and day-by-day scheduling are essential for managing complex integration tasks
Modular design enables incremental testing and validation of individual components before full system assembly
Documentation throughout the integration process supports debugging and future improvements
Final integration week demands focus, organization, and the ability to adapt to unexpected challenges
Contributions
Acknowledgments for contributions and collaborations during the final project week.
Ethical AI Use
Documentation of AI-assisted tasks and tools used during the final project integration week.
📋 General Guidelines: See General Commands for Cursor on the homepage for standard guidelines and commands used consistently throughout documentation development.
Cursor · Project Plan & Weekly Schedule
Comprehensive Cursor AI assistance for outlining the project plan and weekly schedule, including documentation structure, content organization, systematic updates across all week pages and the final project page, media integration, and summary generation workflows.
Cursor AI assistance for Week 14 project integration updates, including Day 2 electrical and mechanical integration documentation, data integration methods refinement, and critical path analysis updates.
Final project integration week focused on bringing together all subsystems into a cohesive MirrorAge system, completing documentation, and preparing for final presentation.
Final integration week focused on bringing all subsystems together, completing hardware fabrication, firmware integration, and documentation for the MirrorAge system presentation.
The act of bringing something to a conclusion or ending in a decisive manner. The ability to efficiently finish tasks and projects with a goal-oriented mindset.
Wednesday
Morning
Publish system integration plan on website
Update weekly assignment sections on final project page (weeks 10-13)
Link final project design files
Update reflections and learnings
Update picture of prism holder
Add final pictures to Slack canvases
Create schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Start CAD model of system
Place final order
Afternoon & Evening
Design:
Boards: Combine OLED screen/accelerometer with pulse oximeter board in a new board (maybe upgrade to small TFT as minor)
Boards: Speaker board with realtime amplifier and TFT (on the load cell fixed board)
Band: Mold design
Cases: 3D print mountable cases for the boards
Integrate designs into final CAD
Document design
Finish CAD model of system
Thursday
Fabricate
Milling boards
Print mold and cast band
Print cases
Solder
Solder components on milled boards
Connect boards with wired (and wireless connection codes)
Finishing
Mirror on screen (easy way with the film)
Documentation
Document fabrication
Friday
Programming
Board level codes
Server level codes
Documentation
Document codes
Completion
Finish anything else
Saturday
Programming & Testing
Demo integrated system
Test integrated system
Documentation
Document testing and evaluation
Review and complete documentation (list of questions)
Make the video by collaging documentation
Sunday
Fill up any gaps
Prepare demo on tensegrity table
Finalize 1-slide
Work on minors
If done, work on if there's time
Monday Morning
Transport demo on tensegrity table
Fill up any gaps
Work on minors
Specific Tasks to Complete This Week
Major Tasks
CAD model of system
Speaker board with realtime amplifier
Combine screen/accelerometer with pulse oximeter board in a new board
Mold and cast band
Design and fabricate casing (print)
Schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Serial connection between pulse oximeter and tiny blinking heart for BPM (BPM from IR, SpO2 from delta)
Combine multiple boards on the same WiFi (switching tabs is easy way, board hosting the webpage querying and update or Python-based server somewhere where everything posting data, Raspberry Pi)
Put+program everything together according to the above (with WiFi for now)
Summary slide and one-minute video for documentation
Conception
Construction
Operation
Minor Tasks
Program microphone/speaker
Fix reaction time delay code
Program LoRa connection
Fix OLED plus WiFi issue
Upgrade to TFT (SPI is very straightforward, design board with either SPI or OLED connection)
Fix heart engraving to center
Engrave K9 glass mirror if it arrives
RD and IRD isolation slit (maybe wick and then cut)
Do the calibration curve for the load cell
Finish cardboard laser cutter origami big mirror frame
If There's Time
Moving base of mirror
Orders
Raspberry Pi Zero (or server host, do some research)
Presentation
Aim for 2.5 minutes because Neil will ask questions
Generally no slides except for 1 open summary slide (have backup slides in case questions come up!)
Related: See the Development Timeline on the final project page for the overall project schedule.
Day 1: Design Integration
Initial system integration work focused on subsystem validation, CAD model consolidation, and design backbone acquisition for band integration.
Subsystem Validation
Conducted comprehensive testing of all subsystems to ensure proper functionality. Identified and resoldered any defective joints, verifying that each subsystem operates correctly before proceeding with full system integration.
CAD Model Consolidation
Exported CAD models of all PCBs in the final design and imported them into a unified CAD assembly. This consolidated model provides a complete view of the system's mechanical integration and spatial relationships.
Integrated CAD Model: Exploded isometric view of the complete system assembly, including all PCBs (pulse oximeter, OLED/accelerometer, speaker/amplifier), main housing with transparent enclosure, and wearable band components. The model shows the spatial relationships between electronic subsystems and mechanical structures, enabling precise integration planning.
Band Design Backbone
Acquired CAD design files for Apple Watch form factor integration, enabling compatibility with existing band designs and standardized watch components. This provides a proven mechanical foundation for the wearable subsystem.
Resuming the daily schedule tomorrow with parallel work streams prioritized according to the critical path. Tasks that cannot be completed during scheduled days will be shifted to buffer days on Saturday and Sunday to maintain project momentum.
Day 2: Electrical and Mechanical Integration
Physical integration of subsystems into the complete demo table assembly, including mechanical component fabrication and electrical board consolidation.
2.1 Mechanical Integration
Mechanical design integration now includes the complete demo table with precise placement of the MirrorAge handgrip subsystem and the aging clock subsystem. The integrated assembly provides a unified platform for system demonstration and testing.
Complete Demo Table Assembly: Integrated mechanical design showing precise placement of the MirrorAge handgrip subsystem and aging clock subsystem on the demo table. The assembly demonstrates the spatial relationships and mounting configurations for both subsystems within the unified demonstration platform.
3D Additive Manufacturing
All 3D additive mechanical components were printed for rapid iterative development. The fabrication process required specific print settings and support strategies for different components:
Printing Initiation: 3D printer starting the fabrication process for mechanical components
Casing Print: Casing component during 3D printing process
Print Configuration Requirements:
Casing: Required organic support structures for complex overhangs
Dock: Required brim adhesion to prevent warping during printing
Bands: Printed using TPU (Thermoplastic Polyurethane) material for flexibility (will spiral into molding and casting in future iterations)
Organic Support Configuration: Slicer settings showing organic support structures for the casing component
Brim Addition: Dock component with brim added to prevent warping during printing
Casing with Organic Support: Printed casing component showing organic support structures
TPU Bands: Flexible wearable band components printed using TPU material
Print Failures and Iteration
Failed Casing Print: Initial casing print failure requiring support structure adjustments
Failed Dock Print: Dock print failure due to warping, resolved with brim addition
Printing Failures: Documentation of various print failures encountered during iterative development
Printing Progress: Successful components showing iterative improvement in print quality
2D Subtractive Manufacturing
The first 2D subtractive mechanical component was debugged and fabricated. The display face component required exporting a DXF of the full face to laser cut an acrylic display that fits the casing precisely. The original display part face was too small because it was filleted, so the edges of the aging clock body were traced and exported for accurate laser cutting.
Laser Cutting Process 1: Initial laser cutting of acrylic display component
Laser Cutting Process 2: Continued laser cutting operation for display face
Acrylic Display Fit: Laser-cut acrylic display component precisely fitted into the casing, demonstrating successful integration of 2D subtractive and 3D additive manufacturing components.
2.2 Electrical Integration
Electrical design integration now combines the accelerometer/camera board with the pulse oximeter board into a single unified design that fits inside the casing. The integrated board may be upgraded to include a small TFT screen in a future iteration if space constraints allow.
Board Design Evolution
Initial Board Design: First integrated board design showing size constraints relative to casing dimensions
Board in Casing: Revised board design fitted within casing dimensional constraints
Final Integrated Board Design: Complete aging clock board design combining accelerometer/camera functionality with pulse oximeter sensors in a single unified PCB layout optimized for casing fit and component placement.
TFT Display Integration
Both the aging clock watch board and the MirrorAge load cell-speaker board have been upgraded to include TFT displays for enhanced visual feedback. The displays use SPI communication for straightforward integration with the ESP32-S3 XIAO microcontroller.
TFT Display Wiring: Pin connection diagram showing SPI interface connections between TFT displays and ESP32-S3 XIAO microcontroller for both watch and MirrorAge boards.
MirrorAge Amplifier Board Design
The MirrorAge amplifier board integrates a real-time audio amplifier with load cell interface and TFT display. The base design includes the amplifier circuit and HX711 load cell interface, with an upgraded version adding the 2.4" ILI9341 TFT display.
Base Amplifier Board: Initial design with real-time amplifier and HX711 load cell interface
Base Board Layout: PCB layout showing component placement for amplifier and load cell interface
TFT Display Component:
1.8" TFT LCD: ST7735 controller, 128×160 pixels. CAD model reference:
GrabCAD ST7735 Model
TFT-Integrated MirrorAge Board: Upgraded PCB design incorporating the 2.4" ILI9341 TFT display alongside the amplifier and load cell interface, enabling visual feedback for grip strength measurements.
Aging Clock Watch Board Design
The aging clock watch board combines pulse oximeter sensors, accelerometer, and camera functionality. The base design uses an OLED display, with an upgraded version incorporating a 1.8" ST7735 TFT display for enhanced visual feedback.
Base Aging Clock Board: Initial design integrating pulse oximeter, accelerometer, and camera with OLED display for wearable watch form factor.
Board Fabrication and Integration
The first version of the aging clock board was milled. The initial board did not fit the casing, requiring either casing adjustment and reprinting, or milling a new miniaturized board with shrunken electronics. Both approaches are being evaluated. The MirrorAge board design has been completed for both base and TFT-integrated versions, ready for milling and testing.
Milled Integrated Board: First version of the integrated aging clock board after PCB milling, showing component placement and routing
Board Fit Test: Milled board nearly fitting in casing, demonstrating the need for dimensional optimization
Board Deflection Fixing: Process of addressing board deflection and mechanical fit issues during integration testing, demonstrating iterative refinement of the electrical-mechanical interface.
Day 3: Fabrication Integration
Comprehensive fabrication integration work combining 2D laser cutting, 3D printing, and PCB milling to create fully integrated subsystems ready for assembly and testing.
2.1 2D Fabrication: Laser Cutting and Vinyl Cutting
The laser-cut acrylic display component was updated in Day 2 and successfully integrated into the watch assembly. The acrylic display provides a clear protective face for the aging clock watch, precisely fitted to the casing dimensions.
The integrated watch assembly demonstrates successful integration of 2D subtractive manufacturing with 3D printed components, creating a cohesive mechanical structure for the wearable subsystem.
2.2 3D Printing: Rigid and Flexible Components
All 3D printed components were fabricated using both rigid and flexible materials. The bands were printed using TPU (Thermoplastic Polyurethane) for flexibility, while rigid components used standard PLA/PETG materials. Additional print details and configuration requirements are documented in Day 2.
The case should also be printed from TPU to improve interlock part fit. The spring-loaded interlock mechanism enables secure band closure while maintaining flexibility for comfortable wear.
TPU Band Print 1: Flexible wearable band component printed using TPU material for comfort and durability
TPU Band Print 2: Flexible band component demonstrating material properties and print quality
Band Closure: Interlock mechanism enabling secure band closure for wearable integration
Rigid Dock: 3D printed dock component for secure board mounting and electrical connection
Assembled Rigid Dock: Complete dock assembly showing board integration and mechanical mounting
Spring-Loaded Interlock: Detailed view of the interlock mechanism enabling secure yet flexible band closure
Spring-Loaded Interlock Operation: Demonstration of the interlock mechanism in action, showing secure closure and release functionality for the wearable band system.
2.3 Milling: Single and Double-Sided Boards
Aging Clock Watch Board
The aging clock watch board was successfully milled. The base design with OLED display worked correctly, and the design has been upgraded to include a TFT display. The new TFT-integrated design will be milled and tested alongside the base OLED version to validate both display options.
Milling Process 1: Initial milling operation for aging clock watch board
Tool Probing: Z-axis calibration and tool location setup for precise milling depth control
Milling Process 2: Continued milling operation showing tool path execution
Milling Process 3: Final milling passes completing board fabrication
Completed Milling: Finished aging clock board after successful milling operation
Vacuuming Debris: Post-milling cleanup process removing copper and substrate debris
Board Removal: Completed aging clock watch board removed from milling machine, ready for component soldering and testing.
MirrorAge Amplifier Board
The base MirrorAge amplifier board milling initially failed due to polygon pour isolation settings. The default isolation distance was set to 0 mil, which caused routing issues. After changing the back-side polygon pour isolation to 32 mil, the milling operation succeeded. When the shop closed, the design was upgraded to include a TFT screen. Both the base design and TFT-integrated versions will be milled together and tested.
Milling Process 1: Initial MirrorAge board milling operation
Milling Process 2: Continued milling showing tool path execution
Failed Milling: Initial milling failure caused by polygon pour isolation set to 0 mil
Failed Milling Video: Demonstration of milling failure due to incorrect isolation settings
Second-Side Fixturing: Board secured for double-sided milling operation
Second-Side Milling: Back-side milling operation for double-sided board
Back-Side Milling: Completing double-sided board fabrication
Fixed Isolation Setting: Polygon pour isolation corrected to 32 mil for proper routing
Successful Milling with Fixed Settings: MirrorAge board milling operation completing successfully after correcting polygon pour isolation to 32 mil, demonstrating the importance of proper PCB design rule configuration.
2.4 Integrating Fabrication
Physical integration of fabricated components demonstrates successful coordination between mechanical and electrical subsystems. The watch board fits within the watch case, and the acrylic display integrates properly. Additional work remains for drilling mounting holes for electronics and routing power connections.
Aging Clock Integration: Watch board and case integration showing proper dimensional fit
Integrated Watch Board: Complete watch board assembly within case, demonstrating successful mechanical integration
Assembled Bands: Complete band assembly with clip mechanism for secure attachment
Interlock Mechanism: Spring-loaded interlock providing secure yet flexible band closure
Interlock Operation: Demonstration of spring-loaded interlock mechanism enabling secure band closure and release for comfortable wearable integration.
TFT Display Upgrades
Both board designs have been upgraded to include TFT displays, and integration testing confirms proper fit. The TFT watch board fits correctly with the TFT display, and both the base and TFT-integrated MirrorAge load cell-speaker boards fit within the gripper enclosure. Additional work is needed for drilling mounting holes and adding hooks for load cell wire routing to the HX711 mounted on the board, as well as routing power connections.
3D printing of board cases (casing, dock, bands) ✓
2D subtractive: laser-cut acrylic display ✓
Physical integration: drilling mounting holes, routing power connections
Mirror film application to screen
Phase 3: Integration & ProgrammingPENDING
Board-level firmware integration
WiFi network coordination between boards
Server-level code development
Serial communication: pulse oximeter to heart display (BPM/SpO2)
System wiring and wireless connection setup
Phase 4: Testing & DocumentationPENDING
Integrated system testing and validation
System evaluation and cost documentation
One-minute video production (conception, construction, operation)
Summary slide preparation
Final documentation review and completion
Current Status
✓
Completed:
Subsystem testing and validation, CAD model consolidation, demo table integration design, aging clock PCB design (accelerometer/camera + pulse oximeter), 3D printing of mechanical components (casing with organic support, dock with brim, TPU bands), laser-cut acrylic display, initial board milling
→
In Progress:
Board fit optimization (casing adjustment vs. miniaturized board), MirrorAge board design (handgrip + speaker + TFT), data integration methods documentation (serial, WiFi, MQTT spiral development)
○
Upcoming:
Component soldering, band mold printing and casting, firmware integration, WiFi/MQTT network setup, system wiring, integrated testing, final documentation
Buffer Days (Saturday & Sunday)
Tasks that cannot be completed during scheduled weekdays will be shifted to Saturday and Sunday buffer days. This ensures the critical path remains on schedule while allowing flexibility for unexpected delays or additional refinement work.
Data Integration Methods to Spirally Develop
Progressive development approach for integrating sensor data streams from multiple subsystems, starting with simple serial communication and evolving to wireless network-based architectures.
Method 1: Serial Communication (Easiest)
Direct serial communication through USB cable from computer to microcontroller, using PySerial to stream data. This provides the simplest initial integration path for rapid prototyping and debugging.
Implementation:
USB cable connection from computer to ESP32-S3 microcontroller
PySerial library for Python-based data streaming
Arduino Serial functions for microcontroller-side communication
Configure all microcontrollers as WiFi clients that stream data to a flash web server. This enables wireless communication while maintaining a centralized data aggregation point.
Implementation:
All ESP32-S3 boards configured as WiFi clients on the same network
Central web server (initially laptop-hosted) receives data streams
WiFiClient::write() functions for data transmission
Message Queuing Telemetry Transport (MQTT) provides a lightweight, publish-subscribe messaging protocol ideal for IoT device communication. This approach enables decentralized data exchange between all MirrorAge subsystems, allowing each board to publish sensor data and subscribe to relevant topics for coordinated system behavior.
Server Hosting Strategy:
Initial development and testing will use a laptop-hosted MQTT broker. In a later development spiral, the server will be migrated to a dedicated Raspberry Pi Zero or Raspberry Pi 5 for standalone operation and improved system portability. Paho MQTT library has been successfully tested for ESP32-S3 implementation.
Development will progress through these methods in order of complexity, starting with serial communication for rapid prototyping, then moving to WiFi client architecture for wireless operation, and finally implementing MQTT for advanced decentralized communication. Each subsystem board (pulse oximeter, OLED/accelerometer, speaker/amplifier, load cell) will be integrated progressively, enabling:
Incremental complexity management and early validation
Decoupled communication between subsystems
Real-time data streaming from multiple sensors
Scalable architecture for adding new sensor modules
Flexible server deployment (laptop → Raspberry Pi migration path)
Reflections & Learnings
Reflections and key learnings from the final project integration week.
Key Points
System integration requires careful coordination of mechanical, electrical, and software subsystems
Comprehensive planning and day-by-day scheduling are essential for managing complex integration tasks
Modular design enables incremental testing and validation of individual components before full system assembly
Documentation throughout the integration process supports debugging and future improvements
Final integration week demands focus, organization, and the ability to adapt to unexpected challenges
Contributions
Acknowledgments for contributions and collaborations during the final project week.
Ethical AI Use
Documentation of AI-assisted tasks and tools used during the final project integration week.
📋 General Guidelines: See General Commands for Cursor on the homepage for standard guidelines and commands used consistently throughout documentation development.
Cursor · Project Plan & Weekly Schedule
Comprehensive Cursor AI assistance for outlining the project plan and weekly schedule, including documentation structure, content organization, systematic updates across all week pages and the final project page, media integration, and summary generation workflows.
Cursor AI assistance for Week 14 project integration updates, including Day 2 electrical and mechanical integration documentation, data integration methods refinement, and critical path analysis updates.
Final project integration week focused on bringing together all subsystems into a cohesive MirrorAge system, completing documentation, and preparing for final presentation.
Final integration week focused on bringing all subsystems together, completing hardware fabrication, firmware integration, and documentation for the MirrorAge system presentation.
The act of bringing something to a conclusion or ending in a decisive manner. The ability to efficiently finish tasks and projects with a goal-oriented mindset.
Wednesday
Morning
Publish system integration plan on website
Update weekly assignment sections on final project page (weeks 10-13)
Link final project design files
Update reflections and learnings
Update picture of prism holder
Add final pictures to Slack canvases
Create schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Start CAD model of system
Place final order
Afternoon & Evening
Design:
Boards: Combine OLED screen/accelerometer with pulse oximeter board in a new board (maybe upgrade to small TFT as minor)
Boards: Speaker board with realtime amplifier and TFT (on the load cell fixed board)
Band: Mold design
Cases: 3D print mountable cases for the boards
Integrate designs into final CAD
Document design
Finish CAD model of system
Thursday
Fabricate
Milling boards
Print mold and cast band
Print cases
Solder
Solder components on milled boards
Connect boards with wired (and wireless connection codes)
Finishing
Mirror on screen (easy way with the film)
Documentation
Document fabrication
Friday
Programming
Board level codes
Server level codes
Documentation
Document codes
Completion
Finish anything else
Saturday
Programming & Testing
Demo integrated system
Test integrated system
Documentation
Document testing and evaluation
Review and complete documentation (list of questions)
Make the video by collaging documentation
Sunday
Fill up any gaps
Prepare demo on tensegrity table
Finalize 1-slide
Work on minors
If done, work on if there's time
Monday Morning
Transport demo on tensegrity table
Fill up any gaps
Work on minors
Specific Tasks to Complete This Week
Major Tasks
CAD model of system
Speaker board with realtime amplifier
Combine screen/accelerometer with pulse oximeter board in a new board
Mold and cast band
Design and fabricate casing (print)
Schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Serial connection between pulse oximeter and tiny blinking heart for BPM (BPM from IR, SpO2 from delta)
Combine multiple boards on the same WiFi (switching tabs is easy way, board hosting the webpage querying and update or Python-based server somewhere where everything posting data, Raspberry Pi)
Put+program everything together according to the above (with WiFi for now)
Summary slide and one-minute video for documentation
Conception
Construction
Operation
Minor Tasks
Program microphone/speaker
Fix reaction time delay code
Program LoRa connection
Fix OLED plus WiFi issue
Upgrade to TFT (SPI is very straightforward, design board with either SPI or OLED connection)
Fix heart engraving to center
Engrave K9 glass mirror if it arrives
RD and IRD isolation slit (maybe wick and then cut)
Do the calibration curve for the load cell
Finish cardboard laser cutter origami big mirror frame
If There's Time
Moving base of mirror
Orders
Raspberry Pi Zero (or server host, do some research)
Presentation
Aim for 2.5 minutes because Neil will ask questions
Generally no slides except for 1 open summary slide (have backup slides in case questions come up!)
Related: See the Development Timeline on the final project page for the overall project schedule.
Day 1: Design Integration
Initial system integration work focused on subsystem validation, CAD model consolidation, and design backbone acquisition for band integration.
Subsystem Validation
Conducted comprehensive testing of all subsystems to ensure proper functionality. Identified and resoldered any defective joints, verifying that each subsystem operates correctly before proceeding with full system integration.
CAD Model Consolidation
Exported CAD models of all PCBs in the final design and imported them into a unified CAD assembly. This consolidated model provides a complete view of the system's mechanical integration and spatial relationships.
Integrated CAD Model: Exploded isometric view of the complete system assembly, including all PCBs (pulse oximeter, OLED/accelerometer, speaker/amplifier), main housing with transparent enclosure, and wearable band components. The model shows the spatial relationships between electronic subsystems and mechanical structures, enabling precise integration planning.
Band Design Backbone
Acquired CAD design files for Apple Watch form factor integration, enabling compatibility with existing band designs and standardized watch components. This provides a proven mechanical foundation for the wearable subsystem.
Resuming the daily schedule tomorrow with parallel work streams prioritized according to the critical path. Tasks that cannot be completed during scheduled days will be shifted to buffer days on Saturday and Sunday to maintain project momentum.
Day 2: Electrical and Mechanical Integration
Physical integration of subsystems into the complete demo table assembly, including mechanical component fabrication and electrical board consolidation.
2.1 Mechanical Integration
Mechanical design integration now includes the complete demo table with precise placement of the MirrorAge handgrip subsystem and the aging clock subsystem. The integrated assembly provides a unified platform for system demonstration and testing.
Complete Demo Table Assembly: Integrated mechanical design showing precise placement of the MirrorAge handgrip subsystem and aging clock subsystem on the demo table. The assembly demonstrates the spatial relationships and mounting configurations for both subsystems within the unified demonstration platform.
3D Additive Manufacturing
All 3D additive mechanical components were printed for rapid iterative development. The fabrication process required specific print settings and support strategies for different components:
Printing Initiation: 3D printer starting the fabrication process for mechanical components
Casing Print: Casing component during 3D printing process
Print Configuration Requirements:
Casing: Required organic support structures for complex overhangs
Dock: Required brim adhesion to prevent warping during printing
Bands: Printed using TPU (Thermoplastic Polyurethane) material for flexibility (will spiral into molding and casting in future iterations)
Organic Support Configuration: Slicer settings showing organic support structures for the casing component
Brim Addition: Dock component with brim added to prevent warping during printing
Casing with Organic Support: Printed casing component showing organic support structures
TPU Bands: Flexible wearable band components printed using TPU material
Print Failures and Iteration
Failed Casing Print: Initial casing print failure requiring support structure adjustments
Failed Dock Print: Dock print failure due to warping, resolved with brim addition
Printing Failures: Documentation of various print failures encountered during iterative development
Printing Progress: Successful components showing iterative improvement in print quality
2D Subtractive Manufacturing
The first 2D subtractive mechanical component was debugged and fabricated. The display face component required exporting a DXF of the full face to laser cut an acrylic display that fits the casing precisely. The original display part face was too small because it was filleted, so the edges of the aging clock body were traced and exported for accurate laser cutting.
Laser Cutting Process 1: Initial laser cutting of acrylic display component
Laser Cutting Process 2: Continued laser cutting operation for display face
Acrylic Display Fit: Laser-cut acrylic display component precisely fitted into the casing, demonstrating successful integration of 2D subtractive and 3D additive manufacturing components.
2.2 Electrical Integration
Electrical design integration now combines the accelerometer/camera board with the pulse oximeter board into a single unified design that fits inside the casing. The integrated board may be upgraded to include a small TFT screen in a future iteration if space constraints allow.
Board Design Evolution
Initial Board Design: First integrated board design showing size constraints relative to casing dimensions
Board in Casing: Revised board design fitted within casing dimensional constraints
Final Integrated Board Design: Complete aging clock board design combining accelerometer/camera functionality with pulse oximeter sensors in a single unified PCB layout optimized for casing fit and component placement.
TFT Display Integration
Both the aging clock watch board and the MirrorAge load cell-speaker board have been upgraded to include TFT displays for enhanced visual feedback. The displays use SPI communication for straightforward integration with the ESP32-S3 XIAO microcontroller.
TFT Display Wiring: Pin connection diagram showing SPI interface connections between TFT displays and ESP32-S3 XIAO microcontroller for both watch and MirrorAge boards.
MirrorAge Amplifier Board Design
The MirrorAge amplifier board integrates a real-time audio amplifier with load cell interface and TFT display. The base design includes the amplifier circuit and HX711 load cell interface, with an upgraded version adding the 2.4" ILI9341 TFT display.
Base Amplifier Board: Initial design with real-time amplifier and HX711 load cell interface
Base Board Layout: PCB layout showing component placement for amplifier and load cell interface
TFT Display Component:
1.8" TFT LCD: ST7735 controller, 128×160 pixels. CAD model reference:
GrabCAD ST7735 Model
TFT-Integrated MirrorAge Board: Upgraded PCB design incorporating the 2.4" ILI9341 TFT display alongside the amplifier and load cell interface, enabling visual feedback for grip strength measurements.
Aging Clock Watch Board Design
The aging clock watch board combines pulse oximeter sensors, accelerometer, and camera functionality. The base design uses an OLED display, with an upgraded version incorporating a 1.8" ST7735 TFT display for enhanced visual feedback.
Base Aging Clock Board: Initial design integrating pulse oximeter, accelerometer, and camera with OLED display for wearable watch form factor.
Board Fabrication and Integration
The first version of the aging clock board was milled. The initial board did not fit the casing, requiring either casing adjustment and reprinting, or milling a new miniaturized board with shrunken electronics. Both approaches are being evaluated. The MirrorAge board design has been completed for both base and TFT-integrated versions, ready for milling and testing.
Milled Integrated Board: First version of the integrated aging clock board after PCB milling, showing component placement and routing
Board Fit Test: Milled board nearly fitting in casing, demonstrating the need for dimensional optimization
Board Deflection Fixing: Process of addressing board deflection and mechanical fit issues during integration testing, demonstrating iterative refinement of the electrical-mechanical interface.
Day 3: Fabrication Integration
Comprehensive fabrication integration work combining 2D laser cutting, 3D printing, and PCB milling to create fully integrated subsystems ready for assembly and testing.
2.1 2D Fabrication: Laser Cutting and Vinyl Cutting
The laser-cut acrylic display component was updated in Day 2 and successfully integrated into the watch assembly. The acrylic display provides a clear protective face for the aging clock watch, precisely fitted to the casing dimensions.
The integrated watch assembly demonstrates successful integration of 2D subtractive manufacturing with 3D printed components, creating a cohesive mechanical structure for the wearable subsystem.
2.2 3D Printing: Rigid and Flexible Components
All 3D printed components were fabricated using both rigid and flexible materials. The bands were printed using TPU (Thermoplastic Polyurethane) for flexibility, while rigid components used standard PLA/PETG materials. Additional print details and configuration requirements are documented in Day 2.
The case should also be printed from TPU to improve interlock part fit. The spring-loaded interlock mechanism enables secure band closure while maintaining flexibility for comfortable wear.
TPU Band Print 1: Flexible wearable band component printed using TPU material for comfort and durability
TPU Band Print 2: Flexible band component demonstrating material properties and print quality
Band Closure: Interlock mechanism enabling secure band closure for wearable integration
Rigid Dock: 3D printed dock component for secure board mounting and electrical connection
Assembled Rigid Dock: Complete dock assembly showing board integration and mechanical mounting
Spring-Loaded Interlock: Detailed view of the interlock mechanism enabling secure yet flexible band closure
Spring-Loaded Interlock Operation: Demonstration of the interlock mechanism in action, showing secure closure and release functionality for the wearable band system.
2.3 Milling: Single and Double-Sided Boards
Aging Clock Watch Board
The aging clock watch board was successfully milled. The base design with OLED display worked correctly, and the design has been upgraded to include a TFT display. The new TFT-integrated design will be milled and tested alongside the base OLED version to validate both display options.
Milling Process 1: Initial milling operation for aging clock watch board
Tool Probing: Z-axis calibration and tool location setup for precise milling depth control
Milling Process 2: Continued milling operation showing tool path execution
Milling Process 3: Final milling passes completing board fabrication
Completed Milling: Finished aging clock board after successful milling operation
Vacuuming Debris: Post-milling cleanup process removing copper and substrate debris
Board Removal: Completed aging clock watch board removed from milling machine, ready for component soldering and testing.
MirrorAge Amplifier Board
The base MirrorAge amplifier board milling initially failed due to polygon pour isolation settings. The default isolation distance was set to 0 mil, which caused routing issues. After changing the back-side polygon pour isolation to 32 mil, the milling operation succeeded. When the shop closed, the design was upgraded to include a TFT screen. Both the base design and TFT-integrated versions will be milled together and tested.
Milling Process 1: Initial MirrorAge board milling operation
Milling Process 2: Continued milling showing tool path execution
Failed Milling: Initial milling failure caused by polygon pour isolation set to 0 mil
Failed Milling Video: Demonstration of milling failure due to incorrect isolation settings
Second-Side Fixturing: Board secured for double-sided milling operation
Second-Side Milling: Back-side milling operation for double-sided board
Back-Side Milling: Completing double-sided board fabrication
Fixed Isolation Setting: Polygon pour isolation corrected to 32 mil for proper routing
Successful Milling with Fixed Settings: MirrorAge board milling operation completing successfully after correcting polygon pour isolation to 32 mil, demonstrating the importance of proper PCB design rule configuration.
2.4 Integrating Fabrication
Physical integration of fabricated components demonstrates successful coordination between mechanical and electrical subsystems. The watch board fits within the watch case, and the acrylic display integrates properly. Additional work remains for drilling mounting holes for electronics and routing power connections.
Aging Clock Integration: Watch board and case integration showing proper dimensional fit
Integrated Watch Board: Complete watch board assembly within case, demonstrating successful mechanical integration
Assembled Bands: Complete band assembly with clip mechanism for secure attachment
Interlock Mechanism: Spring-loaded interlock providing secure yet flexible band closure
Interlock Operation: Demonstration of spring-loaded interlock mechanism enabling secure band closure and release for comfortable wearable integration.
TFT Display Upgrades
Both board designs have been upgraded to include TFT displays, and integration testing confirms proper fit. The TFT watch board fits correctly with the TFT display, and both the base and TFT-integrated MirrorAge load cell-speaker boards fit within the gripper enclosure. Additional work is needed for drilling mounting holes and adding hooks for load cell wire routing to the HX711 mounted on the board, as well as routing power connections.
3D printing of board cases (casing, dock, bands) ✓
2D subtractive: laser-cut acrylic display ✓
Physical integration: drilling mounting holes, routing power connections
Mirror film application to screen
Phase 3: Integration & ProgrammingPENDING
Board-level firmware integration
WiFi network coordination between boards
Server-level code development
Serial communication: pulse oximeter to heart display (BPM/SpO2)
System wiring and wireless connection setup
Phase 4: Testing & DocumentationPENDING
Integrated system testing and validation
System evaluation and cost documentation
One-minute video production (conception, construction, operation)
Summary slide preparation
Final documentation review and completion
Current Status
✓
Completed:
Subsystem testing and validation, CAD model consolidation, demo table integration design, aging clock PCB design (accelerometer/camera + pulse oximeter), TFT-integrated aging clock board design, MirrorAge board design (base and TFT versions), 3D printing of mechanical components (casing with organic support, dock with brim, TPU bands), laser-cut acrylic display, aging clock board milling, TFT display wiring documentation, fabrication integration testing
→
In Progress:
MirrorAge board milling (base and TFT versions), TFT-integrated aging clock board milling, component soldering, physical integration (mounting holes, power routing), data integration methods documentation (serial, WiFi, MQTT spiral development)
○
Upcoming:
Component soldering, band mold printing and casting, firmware integration, WiFi/MQTT network setup, system wiring, integrated testing, final documentation
Buffer Days (Saturday & Sunday)
Tasks that cannot be completed during scheduled weekdays will be shifted to Saturday and Sunday buffer days. This ensures the critical path remains on schedule while allowing flexibility for unexpected delays or additional refinement work.
Data Integration Methods to Spirally Develop
Progressive development approach for integrating sensor data streams from multiple subsystems, starting with simple serial communication and evolving to wireless network-based architectures.
Method 1: Serial Communication (Easiest)
Direct serial communication through USB cable from computer to microcontroller, using PySerial to stream data. This provides the simplest initial integration path for rapid prototyping and debugging.
Implementation:
USB cable connection from computer to ESP32-S3 microcontroller
PySerial library for Python-based data streaming
Arduino Serial functions for microcontroller-side communication
Configure all microcontrollers as WiFi clients that stream data to a flash web server. This enables wireless communication while maintaining a centralized data aggregation point.
Implementation:
All ESP32-S3 boards configured as WiFi clients on the same network
Central web server (initially laptop-hosted) receives data streams
WiFiClient::write() functions for data transmission
Message Queuing Telemetry Transport (MQTT) provides a lightweight, publish-subscribe messaging protocol ideal for IoT device communication. This approach enables decentralized data exchange between all MirrorAge subsystems, allowing each board to publish sensor data and subscribe to relevant topics for coordinated system behavior.
Server Hosting Strategy:
Initial development and testing will use a laptop-hosted MQTT broker. In a later development spiral, the server will be migrated to a dedicated Raspberry Pi Zero or Raspberry Pi 5 for standalone operation and improved system portability. Paho MQTT library has been successfully tested for ESP32-S3 implementation.
Development will progress through these methods in order of complexity, starting with serial communication for rapid prototyping, then moving to WiFi client architecture for wireless operation, and finally implementing MQTT for advanced decentralized communication. Each subsystem board (pulse oximeter, OLED/accelerometer, speaker/amplifier, load cell) will be integrated progressively, enabling:
Incremental complexity management and early validation
Decoupled communication between subsystems
Real-time data streaming from multiple sensors
Scalable architecture for adding new sensor modules
Flexible server deployment (laptop → Raspberry Pi migration path)
Reflections & Learnings
Reflections and key learnings from the final project integration week.
Key Points
System integration requires careful coordination of mechanical, electrical, and software subsystems
Comprehensive planning and day-by-day scheduling are essential for managing complex integration tasks
Modular design enables incremental testing and validation of individual components before full system assembly
Documentation throughout the integration process supports debugging and future improvements
Final integration week demands focus, organization, and the ability to adapt to unexpected challenges
Contributions
Acknowledgments for contributions and collaborations during the final project week.
Ethical AI Use
Documentation of AI-assisted tasks and tools used during the final project integration week.
📋 General Guidelines: See General Commands for Cursor on the homepage for standard guidelines and commands used consistently throughout documentation development.
Cursor · Project Plan & Weekly Schedule
Comprehensive Cursor AI assistance for outlining the project plan and weekly schedule, including documentation structure, content organization, systematic updates across all week pages and the final project page, media integration, and summary generation workflows.
Cursor AI assistance for Week 14 project integration updates, including Day 2 electrical and mechanical integration documentation, data integration methods refinement, and critical path analysis updates.
Final project integration week focused on bringing together all subsystems into a cohesive MirrorAge system, completing documentation, and preparing for final presentation.
Final integration week focused on bringing all subsystems together, completing hardware fabrication, firmware integration, and documentation for the MirrorAge system presentation.
The act of bringing something to a conclusion or ending in a decisive manner. The ability to efficiently finish tasks and projects with a goal-oriented mindset.
Wednesday
Morning
Publish system integration plan on website
Update weekly assignment sections on final project page (weeks 10-13)
Link final project design files
Update reflections and learnings
Update picture of prism holder
Add final pictures to Slack canvases
Create schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Start CAD model of system
Place final order
Afternoon & Evening
Design:
Boards: Combine OLED screen/accelerometer with pulse oximeter board in a new board (maybe upgrade to small TFT as minor)
Boards: Speaker board with realtime amplifier and TFT (on the load cell fixed board)
Band: Mold design
Cases: 3D print mountable cases for the boards
Integrate designs into final CAD
Document design
Finish CAD model of system
Thursday
Fabricate
Milling boards
Print mold and cast band
Print cases
Solder
Solder components on milled boards
Connect boards with wired (and wireless connection codes)
Finishing
Mirror on screen (easy way with the film)
Documentation
Document fabrication
Friday
Programming
Board level codes
Server level codes
Documentation
Document codes
Completion
Finish anything else
Saturday
Programming & Testing
Demo integrated system
Test integrated system
Documentation
Document testing and evaluation
Review and complete documentation (list of questions)
Make the video by collaging documentation
Sunday
Fill up any gaps
Prepare demo on tensegrity table
Finalize 1-slide
Work on minors
If done, work on if there's time
Monday Morning
Transport demo on tensegrity table
Fill up any gaps
Work on minors
Specific Tasks to Complete This Week
Major Tasks
CAD model of system
Speaker board with realtime amplifier
Combine screen/accelerometer with pulse oximeter board in a new board
Mold and cast band
Design and fabricate casing (print)
Schematic between boards (wired and wireless) — updated system diagram on PPT-like page
Serial connection between pulse oximeter and tiny blinking heart for BPM (BPM from IR, SpO2 from delta)
Combine multiple boards on the same WiFi (switching tabs is easy way, board hosting the webpage querying and update or Python-based server somewhere where everything posting data, Raspberry Pi)
Put+program everything together according to the above (with WiFi for now)
Summary slide and one-minute video for documentation
Conception
Construction
Operation
Minor Tasks
Program microphone/speaker
Fix reaction time delay code
Program LoRa connection
Fix OLED plus WiFi issue
Upgrade to TFT (SPI is very straightforward, design board with either SPI or OLED connection)
Fix heart engraving to center
Engrave K9 glass mirror if it arrives
RD and IRD isolation slit (maybe wick and then cut)
Do the calibration curve for the load cell
Finish cardboard laser cutter origami big mirror frame
If There's Time
Moving base of mirror
Orders
Raspberry Pi Zero (or server host, do some research)
Presentation
Aim for 2.5 minutes because Neil will ask questions
Generally no slides except for 1 open summary slide (have backup slides in case questions come up!)
Related: See the Development Timeline on the final project page for the overall project schedule.
Day 1: Design Integration
Initial system integration work focused on subsystem validation, CAD model consolidation, and design backbone acquisition for band integration.
Subsystem Validation
Conducted comprehensive testing of all subsystems to ensure proper functionality. Identified and resoldered any defective joints, verifying that each subsystem operates correctly before proceeding with full system integration.
CAD Model Consolidation
Exported CAD models of all PCBs in the final design and imported them into a unified CAD assembly. This consolidated model provides a complete view of the system's mechanical integration and spatial relationships.
Integrated CAD Model: Exploded isometric view of the complete system assembly, including all PCBs (pulse oximeter, OLED/accelerometer, speaker/amplifier), main housing with transparent enclosure, and wearable band components. The model shows the spatial relationships between electronic subsystems and mechanical structures, enabling precise integration planning.
Band Design Backbone
Acquired CAD design files for Apple Watch form factor integration, enabling compatibility with existing band designs and standardized watch components. This provides a proven mechanical foundation for the wearable subsystem.
Resuming the daily schedule tomorrow with parallel work streams prioritized according to the critical path. Tasks that cannot be completed during scheduled days will be shifted to buffer days on Saturday and Sunday to maintain project momentum.
Day 2: Electrical and Mechanical Integration
Physical integration of subsystems into the complete demo table assembly, including mechanical component fabrication and electrical board consolidation.
2.1 Mechanical Integration
Mechanical design integration now includes the complete demo table with precise placement of the MirrorAge handgrip subsystem and the aging clock subsystem. The integrated assembly provides a unified platform for system demonstration and testing.
Complete Demo Table Assembly: Integrated mechanical design showing precise placement of the MirrorAge handgrip subsystem and aging clock subsystem on the demo table. The assembly demonstrates the spatial relationships and mounting configurations for both subsystems within the unified demonstration platform.
3D Additive Manufacturing
All 3D additive mechanical components were printed for rapid iterative development. The fabrication process required specific print settings and support strategies for different components:
Printing Initiation: 3D printer starting the fabrication process for mechanical components
Casing Print: Casing component during 3D printing process
Print Configuration Requirements:
Casing: Required organic support structures for complex overhangs
Dock: Required brim adhesion to prevent warping during printing
Bands: Printed using TPU (Thermoplastic Polyurethane) material for flexibility (will spiral into molding and casting in future iterations)
Organic Support Configuration: Slicer settings showing organic support structures for the casing component
Brim Addition: Dock component with brim added to prevent warping during printing
Casing with Organic Support: Printed casing component showing organic support structures
TPU Bands: Flexible wearable band components printed using TPU material
Print Failures and Iteration
Failed Casing Print: Initial casing print failure requiring support structure adjustments
Failed Dock Print: Dock print failure due to warping, resolved with brim addition
Printing Failures: Documentation of various print failures encountered during iterative development
Printing Progress: Successful components showing iterative improvement in print quality
2D Subtractive Manufacturing
The first 2D subtractive mechanical component was debugged and fabricated. The display face component required exporting a DXF of the full face to laser cut an acrylic display that fits the casing precisely. The original display part face was too small because it was filleted, so the edges of the aging clock body were traced and exported for accurate laser cutting.
Laser Cutting Process 1: Initial laser cutting of acrylic display component
Laser Cutting Process 2: Continued laser cutting operation for display face
Acrylic Display Fit: Laser-cut acrylic display component precisely fitted into the casing, demonstrating successful integration of 2D subtractive and 3D additive manufacturing components.
2.2 Electrical Integration Methods to Spirally Develop
Electrical design integration combines multiple subsystems into unified board designs, with progressive upgrades incorporating TFT displays for enhanced visual feedback. The integration follows a spiral development approach, starting with base designs and iteratively adding features like TFT displays as design constraints are validated.
Board Design Evolution
Initial Board Design: First integrated board design showing size constraints relative to casing dimensions
Board in Casing: Revised board design fitted within casing dimensional constraints
Final Integrated Board Design: Complete aging clock board design combining accelerometer/camera functionality with pulse oximeter sensors in a single unified PCB layout optimized for casing fit and component placement.
TFT Display Integration
Both the aging clock watch board and the MirrorAge load cell-speaker board have been upgraded to include TFT displays for enhanced visual feedback. The displays use SPI communication for straightforward integration with the ESP32-S3 XIAO microcontroller.
TFT Display Wiring: Pin connection diagram showing SPI interface connections between TFT displays and ESP32-S3 XIAO microcontroller for both watch and MirrorAge boards.
MirrorAge Amplifier Board Design
The MirrorAge amplifier board integrates a real-time audio amplifier with load cell interface and TFT display. The base design includes the amplifier circuit and HX711 load cell interface, with an upgraded version adding the 2.4" ILI9341 TFT display.
Base Amplifier Board: Initial design with real-time amplifier and HX711 load cell interface
Base Board Layout: PCB layout showing component placement for amplifier and load cell interface
TFT Display Component:
1.8" TFT LCD: ST7735 controller, 128×160 pixels. CAD model reference:
GrabCAD ST7735 Model
TFT-Integrated MirrorAge Board: Upgraded PCB design incorporating the 2.4" ILI9341 TFT display alongside the amplifier and load cell interface, enabling visual feedback for grip strength measurements.
Aging Clock Watch Board Design
The aging clock watch board combines pulse oximeter sensors, accelerometer, and camera functionality. The base design uses an OLED display, with an upgraded version incorporating a 1.8" ST7735 TFT display for enhanced visual feedback.
Base Aging Clock Board: Initial design integrating pulse oximeter, accelerometer, and camera with OLED display for wearable watch form factor.
Board Fabrication and Integration
The first version of the aging clock board was milled. The initial board did not fit the casing, requiring either casing adjustment and reprinting, or milling a new miniaturized board with shrunken electronics. Both approaches are being evaluated. The MirrorAge board design has been completed for both base and TFT-integrated versions, ready for milling and testing.
Milled Integrated Board: First version of the integrated aging clock board after PCB milling, showing component placement and routing
Board Fit Test: Milled board nearly fitting in casing, demonstrating the need for dimensional optimization
Board Deflection Fixing: Process of addressing board deflection and mechanical fit issues during integration testing, demonstrating iterative refinement of the electrical-mechanical interface.
Day 3: Fabrication Integration
Comprehensive fabrication integration work combining 2D laser cutting, 3D printing, and PCB milling to create fully integrated subsystems ready for assembly and testing.
2.1 2D Fabrication: Laser Cutting and Vinyl Cutting
The laser-cut acrylic display component was updated in Day 2 and successfully integrated into the watch assembly. The acrylic display provides a clear protective face for the aging clock watch, precisely fitted to the casing dimensions.
The integrated watch assembly demonstrates successful integration of 2D subtractive manufacturing with 3D printed components, creating a cohesive mechanical structure for the wearable subsystem.
2.2 3D Printing: Rigid and Flexible Components
All 3D printed components were fabricated using both rigid and flexible materials. The bands were printed using TPU (Thermoplastic Polyurethane) for flexibility, while rigid components used standard PLA/PETG materials. Additional print details and configuration requirements are documented in Day 2.
The case should also be printed from TPU to improve interlock part fit. The spring-loaded interlock mechanism enables secure band closure while maintaining flexibility for comfortable wear.
TPU Band Print 1: Flexible wearable band component printed using TPU material for comfort and durability
TPU Band Print 2: Flexible band component demonstrating material properties and print quality
Band Closure: Interlock mechanism enabling secure band closure for wearable integration
Rigid Dock: 3D printed dock component for secure board mounting and electrical connection
Assembled Rigid Dock: Complete dock assembly showing board integration and mechanical mounting
Spring-Loaded Interlock: Detailed view of the interlock mechanism enabling secure yet flexible band closure
Spring-Loaded Interlock Operation: Demonstration of the interlock mechanism in action, showing secure closure and release functionality for the wearable band system.
2.3 Milling: Single and Double-Sided Boards
Aging Clock Watch Board
The aging clock watch board was successfully milled. The base design with OLED display worked correctly, and the design has been upgraded to include a TFT display. The new TFT-integrated design will be milled and tested alongside the base OLED version to validate both display options.
Milling Process 1: Initial milling operation for aging clock watch board
Tool Probing: Z-axis calibration and tool location setup for precise milling depth control
Milling Process 2: Continued milling operation showing tool path execution
Milling Process 3: Final milling passes completing board fabrication
Completed Milling: Finished aging clock board after successful milling operation
Vacuuming Debris: Post-milling cleanup process removing copper and substrate debris
Board Removal: Completed aging clock watch board removed from milling machine, ready for component soldering and testing.
MirrorAge Amplifier Board
The base MirrorAge amplifier board milling initially failed due to polygon pour isolation settings. The default isolation distance was set to 0 mil, which caused routing issues. After changing the back-side polygon pour isolation to 32 mil, the milling operation succeeded. When the shop closed, the design was upgraded to include a TFT screen. Both the base design and TFT-integrated versions will be milled together and tested.
Milling Process 1: Initial MirrorAge board milling operation
Milling Process 2: Continued milling showing tool path execution
Failed Milling: Initial milling failure caused by polygon pour isolation set to 0 mil
Failed Milling Video: Demonstration of milling failure due to incorrect isolation settings
Second-Side Fixturing: Board secured for double-sided milling operation
Second-Side Milling: Back-side milling operation for double-sided board
Back-Side Milling: Completing double-sided board fabrication
Fixed Isolation Setting: Polygon pour isolation corrected to 32 mil for proper routing
Successful Milling with Fixed Settings: MirrorAge board milling operation completing successfully after correcting polygon pour isolation to 32 mil, demonstrating the importance of proper PCB design rule configuration.
2.4 Integrating Fabrication
Physical integration of fabricated components demonstrates successful coordination between mechanical and electrical subsystems. The watch board fits within the watch case, and the acrylic display integrates properly. Additional work remains for drilling mounting holes for electronics and routing power connections.
Aging Clock Integration: Watch board and case integration showing proper dimensional fit
Integrated Watch Board: Complete watch board assembly within case, demonstrating successful mechanical integration
Assembled Bands: Complete band assembly with clip mechanism for secure attachment
Interlock Mechanism: Spring-loaded interlock providing secure yet flexible band closure
Interlock Operation: Demonstration of spring-loaded interlock mechanism enabling secure band closure and release for comfortable wearable integration.
TFT Display Upgrades
Both board designs have been upgraded to include TFT displays, and integration testing confirms proper fit. The TFT watch board fits correctly with the TFT display, and both the base and TFT-integrated MirrorAge load cell-speaker boards fit within the gripper enclosure. Additional work is needed for drilling mounting holes and adding hooks for load cell wire routing to the HX711 mounted on the board, as well as routing power connections.
3D printing of board cases (casing, dock, bands) ✓
2D subtractive: laser-cut acrylic display ✓
Physical integration: drilling mounting holes, routing power connections
Mirror film application to screen
Phase 3: Integration & ProgrammingPENDING
Board-level firmware integration
WiFi network coordination between boards
Server-level code development
Serial communication: pulse oximeter to heart display (BPM/SpO2)
System wiring and wireless connection setup
Phase 4: Testing & DocumentationPENDING
Integrated system testing and validation
System evaluation and cost documentation
One-minute video production (conception, construction, operation)
Summary slide preparation
Final documentation review and completion
Current Status
✓
Completed:
Subsystem testing and validation, CAD model consolidation, demo table integration design, aging clock PCB design (accelerometer/camera + pulse oximeter), TFT-integrated aging clock board design, MirrorAge board design (base and TFT versions), 3D printing of mechanical components (casing with organic support, dock with brim, TPU bands), laser-cut acrylic display, aging clock board milling, TFT display wiring documentation, fabrication integration testing
→
In Progress:
MirrorAge board milling (base and TFT versions), TFT-integrated aging clock board milling, component soldering, physical integration (mounting holes, power routing), data integration methods documentation (serial, WiFi, MQTT spiral development)
○
Upcoming:
Component soldering, band mold printing and casting, firmware integration, WiFi/MQTT network setup, system wiring, integrated testing, final documentation
Buffer Days (Saturday & Sunday)
Tasks that cannot be completed during scheduled weekdays will be shifted to Saturday and Sunday buffer days. This ensures the critical path remains on schedule while allowing flexibility for unexpected delays or additional refinement work.
Data Integration Methods to Spirally Develop
Progressive development approach for integrating sensor data streams from multiple subsystems, starting with simple serial communication and evolving to wireless network-based architectures.
Method 1: Serial Communication (Easiest)
Direct serial communication through USB cable from computer to microcontroller, using PySerial to stream data. This provides the simplest initial integration path for rapid prototyping and debugging.
Implementation:
USB cable connection from computer to ESP32-S3 microcontroller
PySerial library for Python-based data streaming
Arduino Serial functions for microcontroller-side communication
Configure all microcontrollers as WiFi clients that stream data to a flash web server. This enables wireless communication while maintaining a centralized data aggregation point.
Implementation:
All ESP32-S3 boards configured as WiFi clients on the same network
Central web server (initially laptop-hosted) receives data streams
WiFiClient::write() functions for data transmission
Message Queuing Telemetry Transport (MQTT) provides a lightweight, publish-subscribe messaging protocol ideal for IoT device communication. This approach enables decentralized data exchange between all MirrorAge subsystems, allowing each board to publish sensor data and subscribe to relevant topics for coordinated system behavior.
Server Hosting Strategy:
Initial development and testing will use a laptop-hosted MQTT broker. In a later development spiral, the server will be migrated to a dedicated Raspberry Pi Zero or Raspberry Pi 5 for standalone operation and improved system portability. Paho MQTT library has been successfully tested for ESP32-S3 implementation.
Development will progress through these methods in order of complexity, starting with serial communication for rapid prototyping, then moving to WiFi client architecture for wireless operation, and finally implementing MQTT for advanced decentralized communication. Each subsystem board (pulse oximeter, OLED/accelerometer, speaker/amplifier, load cell) will be integrated progressively, enabling:
Incremental complexity management and early validation
Decoupled communication between subsystems
Real-time data streaming from multiple sensors
Scalable architecture for adding new sensor modules
Flexible server deployment (laptop → Raspberry Pi migration path)
Reflections & Learnings
Reflections and key learnings from the final project integration week.
Key Points
System integration requires careful coordination of mechanical, electrical, and software subsystems
Comprehensive planning and day-by-day scheduling are essential for managing complex integration tasks
Modular design enables incremental testing and validation of individual components before full system assembly
Documentation throughout the integration process supports debugging and future improvements
Final integration week demands focus, organization, and the ability to adapt to unexpected challenges
Contributions
Acknowledgments for contributions and collaborations during the final project week.
Ethical AI Use
Documentation of AI-assisted tasks and tools used during the final project integration week.
📋 General Guidelines: See General Commands for Cursor on the homepage for standard guidelines and commands used consistently throughout documentation development.
Cursor · Project Plan & Weekly Schedule
Comprehensive Cursor AI assistance for outlining the project plan and weekly schedule, including documentation structure, content organization, systematic updates across all week pages and the final project page, media integration, and summary generation workflows.
Cursor AI assistance for Week 14 project integration updates, including Day 2 electrical and mechanical integration documentation, data integration methods refinement, and critical path analysis updates.
1. Updated Electrical Integration Section (2.2)
- Renamed to "Electrical Integration Methods to Spirally Develop"
- Added TFT wiring table with ESP32-S3 XIAO pin mapping
- Included references to the Seeed Studio guide and other sources
- Added TFT display images (1.8" and 2.4")
- Documented MirrorAge amplifier board design (base and TFT versions)
- Documented aging clock watch board design
- Added board fabrication notes
2. Added Day 3 Fabrication Integration Section
- 2.1 2D Fabrication: Laser cutting and vinyl cutting (with link to Day 2)
- 2.2 3D Printing: Rigid and flexible components with TPU bands, dock, and interlock mechanism
- 2.3 PCB Milling: Single and double-sided boards
- Aging clock board milling process (videos and images)
- MirrorAge board milling (including polygon pour isolation fix)
- 2.4 Integrating Fabrication: Physical integration with TFT upgrade documentation
3. Updated Critical Path Analysis
- Marked completed tasks (TFT board designs, aging clock board milling, etc.)
- Updated in-progress items (MirrorAge board milling, component soldering)
- Updated current status section with Day 3 accomplishments
4. Updated Table of Contents
- Added Day 3 link to navigation
All content is organized with captions, descriptions, and clear step-by-step documentation. The electrical integration section emphasizes the spiral development approach, and the critical path reflects current progress.
UserUnknown
— run the commits and pushes in small <25mb packets to avoid the limit (make sure to push and sync changes with each small commit because the limit is at the sync in the end). Don’t use ffmpeg everything is already compressed, just one file at a time if they are large
AssistantUnknown
Checking git status, then committing and pushing in small batches (<25MB) to avoid size limits.
Checking sizes of changed files to plan small commits:
Committing in small batches: starting with the HTML file, then small images, then videos one at a time.
Committing small image files in batches:
Committing video files one at a time, starting with the smallest:
Verifying all files are committed and pushed:
All changes have been committed and pushed in small batches.
Summary of commits:
1. week14.html - Updated HTML file with Day 3 content
2. Small image files (batch 1) - 8 files (~1.5MB total)
3. Small image files (batch 2) - 8 files (~2MB total)
4. Medium image files (batch 3) - 8 files (~3.5MB total)
5. PNG design files - 3 files (~2.5MB total)
6. Video files - Committed individually, one at a time:
- fixed-isolate-32-mil.mp4 (512K)
- completed-aging-clock-mill.mp4 (960K)
- milling-mirrorage-3-failed.mp4 (1.0M)
- milling-aging-clock-3.mp4 (2.1M)
- milling-backside.mp4 (2.1M)
- milling-mirrorage-1.mp4 (2.1M)
- spring-loaded-interlock.mp4 (2.1M)
- milling-mirrorage-2.mp4 (3.1M)
- second-side.mp4 (3.1M)
- vacuuming-aging-clock-mill.mp4 (3.1M)
- milling-aging-clock.mp4 (5.1M)
- milling-aging-clock-2.mp4 (7.1M)
All files are committed and pushed. Each commit was pushed immediately to sync with the remote, keeping each push under 25MB. The working tree is clean.
Download Options
For the complete technical details and full conversation transcript:
