To build a stable prototype while our PCB was in manufacturing, we've come up with a great way to package our system into a small box, while still keeping it highly physically stable.
The Frontof the 3 layer system, comprising of everything required for our DC-boosting. Along with this, we have an adjustability parameter to allow us to screw left or right to turn up or down our voltage boosting!
The middle of the 3 layer system, comprising of soldered wiring and an n-channel mosfet that is turned on by ESP32 to allow for high voltage into our 24v rated speaker.
The rear of the 3 layer system, comprising of only an esp32 soldered in.
The orientation of which our system will fit into our 3d printed encasing.
Our workaround was extremely successful! Here is our system snuggly screwed into our extremely durable 3D printed box.
We perfectly calculated all fitments and sanded our ABS material encasing to ensure our speaker and ultrasonic sensors are a literal perfect fit into the front face.
Our 18650 battery is stuck down with a strong adhesive and our electronics system is screwed to the back with 4 bolts/nuts.
A hole on the front face allows for the adjustment of the potentiometer, controlling how high we boost voltage for a louder/quieter speaker operation.
A hole in the back is for the resetting of the ESP32 in case of any sort of malfunction. It's important to note that the Adafruit ESP32 Huzzah has an auto bootloader function, so no hole for the boot button is required.
All screws are small M2-sized screws. During demo day, we stood on top of our encasing and gave it some fairly sturdy stomps to find that our encasing was indeed strong enough to support a minimum of approximately 200lb of force in all directions. With 1/3 inch walls and 100% infill, the ABZ team wanted to ensure intruders would have a hard time breaking/breaking into our system.