Wireless ESP32 Controller – Mechatronic Product Design & 3D Printed Prototype

Wireless ESP32 Controller – Functional Mechatronic Prototype Design and development of a custom wireless 10-button controller created as part of a sports scoring system. The project involved the complete mechanical integration of the electronics into a compact handheld enclosure, including an ESP32 development board, ten physical switches, voltage regulation, a rechargeable lithium battery, charging electronics and all the required internal mounting features. The enclosure and internal layout were designed considering component positioning, accessibility, assembly, ergonomics and 3D-print manufacturing. The design includes dedicated supports for the PCB and electronic modules, switch mounting structures, fastening points and external access for charging. The complete enclosure was manufactured using 3D printing and assembled into a functional physical prototype, allowing the mechanical design, electronic integration and overall concept to be validated in a real working device. This physical ESP32 controller was the first functional version of the system. After validating the concept with the manufactured hardware prototype, the project evolved into a fully digital mobile controller. The final image shows this later version running on a smartphone, where the physical 10-button interface was recreated as a software-based wireless control system. This project demonstrates the complete evolution of a mechatronic product from CAD design and electronic integration to physical prototyping, functional validation and subsequent migration to a software-based solution. Skills demonstrated: mechanical product design, electronic enclosure design, ESP32 integration, component packaging, CAD assembly, prototyping, design for additive manufacturing and mechatronic system development.