06 Aug 2026 · First prototype

Why the first board is large.

The 100 mm board gave us enough room to connect probes, swap the controller and find problems without working under a microscope.

MAX30001 section of the first HydroGuard prototype schematic
The MAX30001, electrode connections, SPI, power and test point.

HydroGuard uses four electrodes. The outer pair sends a small alternating current through the upper arm. The inner pair measures the resulting voltage. Separating these two jobs makes the measurement less sensitive to the resistance where each electrode touches the skin.

The first board gives the MAX30001 its own 1.8 V supply and clock. Every electrode path has a 1 kΩ series resistor, and the reference voltage has a test point. The ESP32-C6 module is removable, which helped when we needed to probe signals or change the controller.

Routing around the MAX30001 on the first HydroGuard prototype
Routing around the MAX30001 on the first board.
The manufactured first prototype board on pink anti-static foam
The first prototype as it arrived from the fab.

Four electrodes on an elastic band

We use 12 mm sew-on snaps to connect the electrodes. They are easy to replace and easy to position on an elastic band. The band holds them flat against the arm without needing a custom adhesive patch.

Sew-on snap electrodes mounted on the elastic band
12 mm sew-on snaps on the elastic band.
The strap should hold the electrodes in place without feeling tight. Pressure changes the reading, so a tighter band is not automatically a better band.

Measuring the battery

A 2 MΩ and 1 MΩ resistor divider brings the LiPo voltage into the range of the controller’s analog input. A capacitor beside the input makes the high-resistance divider easier for the ADC to read. The tradeoff is a short settling time before each measurement.

A status light that is not essential

The first board has an SK6812 status LED. It worked, but the board powers it below the minimum voltage in its datasheet. The firmware therefore treats it as optional. If the LED is missing or fails, the impedance measurement still works.

Why we started at 32 µA

The first tests used a 32 µA measurement current. It was a conservative starting point while we checked the electrode contact and the signal range. Higher settings remain available, but they were not needed to prove the circuit.

The large board did its job. It gave us a clear view of the signal path and enough access to fix the first problems. The next board can now focus on size, power use and wearing comfort.