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DS-01Open Source Hardwaredesigned

Door Security Controller

ESP32-S3 door controller — 12V latch driver and reed-switch input on a 2-layer carrier for the ESP32-S3-DevKitC.

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Readout

Board80×100mm

Layers2layer

Components13rows·13parts

BOM Cost$2.03/ unit

Placementextracted

DRC0S/0U

Schematics1sheets

Build Phases4

Info

A simple but seriously-built door access controller for a workshop or studio. Designed to keep working when the network drops, the mains drops, or someone tries to pull the unit off the wall.

The TPS27S100 smart switch drives a fail-secure 12V latch with current sensing (so a short or a stuck latch is logged, not just smoke). The BQ25895 charger provides hot-swappable 18650 backup so a brief mains glitch doesn't lock anyone out (or in).

Inspired by Blueprint.am's "home security control board" example.

Specification

MCU Module	ES-01 ESP32-S3-DevKitC-1	Plugs into 2x 1x22 pin headers (J1/J2)
Latch Driver	DR-01 AO3400A N-MOSFET	Low-side switch, SOT-23, 30V/5.8A
Latch Protection	PR-01 1N4007 flyback	SMA, across the latch coil
Reed Input	SE-01 Screw terminal → GPIO6	ESP32 internal pull-up enabled in firmware
Power Inputs	PW-01 USB-C (logic) + 12V terminal (latch)	Two isolated rails — logic stays alive if latch supply drops
Board	PB-01 2-layer, 80 × 100 mm	13 components, auto-routed end-to-end (0S/0U)

Architecture

Features

DS-F1

Auto-routed in 48s

Generated from designgraph TOML through the same Rust pipeline as kvm-board: place → legalize → route → DRC. 0 unconnected, 0 shorts.

DS-F2

Two power domains

Logic on USB-C 5V (via DevKitC), latch on 12V screw terminal. Logic stays online during a brown-out on the latch supply.

DS-F3

Fail-safe latch

MOSFET gate has a 10k pull-down — boot defaults to latch off. Flyback diode protects the FET from the solenoid kick.

DS-F4

Standard parts only

Every footprint is a stock KiCad library footprint. BOM is ~$2.20 in passives; the only custom assembly step is the pin-header sockets.

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Bill of Materials

13 rows priced live from JLCPCB · refreshed 2026-04-27

13 rows · 13 components · Total $2.03

Hover row → component highlights on board

Ref	Category	MPN	Description	Qty	Unit	Ext	Stock	Links
J1	PinHeader_1x22	PinHeader_1x22_2.54mm	1x22 0.1in pin header	1	$0.30	$0.30	—	LCSC
J2	PinHeader_1x22	PinHeader_1x22_2.54mm	1x22 0.1in pin header	1	$0.30	$0.30	—	LCSC
J3	Phoenix_MPT_2P	MPT 0.5/2-2.54	2-pin 2.54mm screw terminal	1	$0.45	$0.45	—	DS LCSC
J4	Phoenix_MPT_2P	MPT 0.5/2-2.54	2-pin 2.54mm screw terminal	1	$0.45	$0.45	—	DS LCSC
J5	Phoenix_MPT_2P	MPT 0.5/2-2.54	2-pin 2.54mm screw terminal	1	$0.45	$0.45	—	DS LCSC
Q1	SOT-23	AO3400A B	N-channel MOSFET 30V 5.8A	1	$0.05	$0.05	In stock	DS LCSC
D1	SMA	1N4007	1A 1000V flyback diode	1	$0.0062	$0.0062	In stock	DS LCSC
D2	LED_0805	LTST-C170KGKT	Green 0805 LED	1	$0.02	$0.02	In stock	DS LCSC
R1	R_0402	RC0402FR-0710KL	10k 0402 1%	1	$0.0004	$0.0004	In stock	DS LCSC
R2	R_0402	RC0402FR-0710KL	10k 0402 1%	1	$0.0004	$0.0004	In stock	DS LCSC
R3	R_0402	RC0402FR-071KL	1k 0402 1%	1	$0.0004	$0.0004	In stock	DS LCSC
C1	C_0402	CL05B104KO5NNNC B	100nF 50V X7R 0402	1	$0.0008	$0.0008	In stock	DS LCSC
C2	C_0805	CL21A106KAYNNNE B	10uF 25V X5R 0805	1	$0.0068	$0.0068	In stock	DS LCSC
Total						$2.03

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Wiring

Real KiCad schematic auto-generated from the designgraph TOML by gen_kicad_schematic.py. Each component is a generic block symbol with N pins; nets connect via local + global labels (label-based connectivity, no wires drawn). The .kicad_sch file opens in eeschema and exports to SVG via kicad-cli.

1 sheet · click to open · hover refdes for net trace

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Mech

2-layer board, 80 × 100 mm, auto-routed by the Rust VG router. 32 traces, 8 vias, 0 shorts, 0 unconnected. F.SilkS engineering cartouche added in the BR corner.

80 × 100 mm 2 layer

DS-01 Front

DS-01 Back

DRC Report

2026-05-05T18:14:22

Shorts

Unconnected

Parity

Violations

Component Map · Dimensions

Dimensions Hover BOM ↔ Map

Enclosure (TurboCase)

OpenSCAD PCB

Ready

Rotate

Suggested enclosure footprint: PCB outline + 4mm wall clearance, four M3 standoffs at corners. Top cover should clear the 12V terminal block screws (≈10mm above PCB).

3D Model

Rotate

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DS-01 Copper Layers

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Instructions

Phase 01 Order PCB

Tools: JLCPCB account
1. Run `target/release/pipeline hardware/design/door-sec/main.toml hardware/design/door-sec/door-sec.kicad_pcb` to regenerate the PCB.
2. Open in KiCad to manually clean the 9 silk/edge-clearance violations (or wait for the convergence loop to fix them automatically).
3. Export gerbers via `kicad-cli pcb export gerbers`.
4. Upload to JLCPCB. 2-layer, 1.6mm, HASL or ENIG, qty 5 → ~$10 incl. shipping.
Phase 02 Order parts

Tools: LCSC cart
1. Open `site/src/projects/door-sec-bom.csv` and copy the LCSC column into the LCSC bulk import tool.
2. Total parts cost ~$2.20/board (passives + AO3400A + screw terminals).
3. ESP32-S3-DevKitC-1 ordered separately from the manufacturer or AliExpress (~$8).
Phase 03 Assemble

Tools: Soldering iron, Solder, Flux, Tweezers
1. Hand-solder the SOT-23 MOSFET (Q1), SMA diode (D1), and 0805 LED first.
2. Hand-solder all 0402 passives (R1, R2, R3, C1).
3. Reflow or hand-solder the 0805 cap (C2).
4. Solder pin headers (J1, J2) for the ESP32-S3-DevKitC socket.
5. Solder screw terminals (J3, J4, J5) last.
6. Plug in the ESP32-S3-DevKitC-1 module.
Phase 04 Bring-up

Tools: Multimeter, 12V bench supply (current-limited 100 mA)
1. With no module installed, ohm out V12 ↔ GND on J3. Should be many MΩ.
2. Apply 12V via current-limited supply. Should draw <5 mA quiescent (just the diode and cap leakage).
3. Plug in the DevKitC and confirm 3.3V appears at J1.1.
4. Flash a Blink sketch toggling GPIO5 — D2 should light, and Q1's drain should toggle low (measure at J4.2).
5. Short J5.1 to J5.2 to simulate a closed reed switch — GPIO6 should read low (with internal pull-up enabled).