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Portable PCB Tester Tool

compute Raspberry Pi 5 + Custom Interface battery Integrated LiPo + Fuel Gauge enclosure Layered Modular 3D Chassis application Field Flashing & Telematics QA

A rugged, handheld diagnostic and firmware flashing tool built for field engineers and warehouse technicians. Packages a Raspberry Pi 5, touch display, battery power management, and custom breakout harnesses into a compact, impact-resistant 3D-printed enclosure.

How: Designed an enclosure in CAD with compartments for the screen, battery, ports, and test board. Assembled the tool with 3D printing and organized internal wiring to components. Programmed a GUI on a Raspberry Pi 5 embedded in the tool to streamline firmware flashing and device diagnostics during field use.
How: Designed an enclosure in CAD with compartments for the screen, battery, ports, and test board. Assembled the tool with 3D printing and organized internal wiring to components. Programmed a GUI on a Raspberry Pi 5 embedded in the tool to streamline firmware flashing and device diagnostics during field use.
How: Designed an enclosure in CAD with compartments for the screen, battery, ports, and test board. Assembled the tool with 3D printing and organized internal wiring to components. Programmed a GUI on a Raspberry Pi 5 embedded in the tool to streamline firmware flashing and device diagnostics during field use.
• 3D Printed Layers: Printed prototype layer frames and to separate components and test fit and tolerancing.
• 3D Printed Layers: Printed prototype layer frames and to separate components and test fit and tolerancing.
• 3D Printed Layers: Printed prototype layer frames and to separate components and test fit and tolerancing.
• Wire Routing: 3D printed layers include strategic slots for clean wire routing, allowing cables to be layered between sections for a compact and organized design.
• Wire Routing: 3D printed layers include strategic slots for clean wire routing, allowing cables to be layered between sections for a compact and organized design.
[01/08] How: Designed an enclosure in CAD with compartments for the screen, battery, ports, and test board. Assembled the tool with 3D printing and organized internal wiring to components. Programmed a GUI on a Raspberry Pi 5 embedded in the tool to streamline firmware flashing and device diagnostics during field use.

01Mechanical Design & CAD Assembly

Comprehensive SolidWorks 3D CAD modeling, multi-body kinematics, tolerance stack-up analysis, and assembly architecture.

01.1 Handheld Field Tester Architecture & Ergonomic CAD

Compact, rugged handheld diagnostic tool CAD assembly designed for single-operator field testing of automated sorting equipment.

Full Assembly: CAD model of the portable tester tool, designed as a compact all-in-one device for field use.
Full Assembly: CAD model of the portable tester tool, designed as a compact all-in-one device for field use.
Full Assembly: CAD model of the portable tester tool, designed as a compact all-in-one device for field use.
[01/03] Full Assembly: CAD model of the portable tester tool, designed as a compact all-in-one device for field use.

01.2 Modular Sliding Port Covers & Dust Seals

Sliding dust covers and flush-mount bezels protecting Raspberry Pi 5 USB ports, HDMI debug outputs, battery charging, and wire harness connectors.

Port Cutout Covers: Raspberry Pi 5 USB ports, battery interface, and harness connector all feature precise cutouts and sliding covers that mount cleanly to the enclosure for a polished, integrated design.
Port Cutout Covers: Raspberry Pi 5 USB ports, battery interface, and harness connector all feature precise cutouts and sliding covers that mount cleanly to the enclosure for a polished, integrated design.
Port Cutout Covers: Raspberry Pi 5 USB ports, battery interface, and harness connector all feature precise cutouts and sliding covers that mount cleanly to the enclosure for a polished, integrated design.
Cover Attachment: Port covers glues to the enclosure and provides a clean solution for covering cutouts.
Cover Attachment: Port covers glues to the enclosure and provides a clean solution for covering cutouts.
[01/05] Port Cutout Covers: Raspberry Pi 5 USB ports, battery interface, and harness connector all feature precise cutouts and sliding covers that mount cleanly to the enclosure for a polished, integrated design.

01.3 Stacked Multi-Layer Packaging & Electronics Bays

Four-tier modular internal skeleton separating touchscreen display, Raspberry Pi compute board, test interface PCB, and battery power supply.

Layered Component Assembly: Exploded view showing organized component layers with dedicated spaces for electronics and wire routing, enabling a clean and compact internal layout.
Layered Component Assembly: Exploded view showing organized component layers with dedicated spaces for electronics and wire routing, enabling a clean and compact internal layout.
Electronics Integration: Each enclosure layer houses a specific component—battery, PCB tester, Raspberry Pi, and screen—for a compact and organized internal layout.
Electronics Integration: Each enclosure layer houses a specific component—battery, PCB tester, Raspberry Pi, and screen—for a compact and organized internal layout.
[01/04] Layered Component Assembly: Exploded view showing organized component layers with dedicated spaces for electronics and wire routing, enabling a clean and compact internal layout.

02Prototyping, 3D Printing & Fabrication

Rapid prototyping iterations, slicing optimization (Bambu Studio / PrusaSlicer), material selection (PLA / PETG / Carbon Fiber), and precision fit checks.

02.1 Multi-Layer Internal Frame Prototyping

Additive manufacturing of stacked intermediate frames to evaluate tolerance stack-up and verify rigid screw anchor points.

• 3D Printed Layers: Printed prototype layer frames and to separate components and test fit and tolerancing.
• 3D Printed Layers: Printed prototype layer frames and to separate components and test fit and tolerancing.
• 3D Printed Layers: Printed prototype layer frames and to separate components and test fit and tolerancing.
• Testing Component Layers: Assembled stacked enclosure layers to evaluate tolerancing and component fit.
• Testing Component Layers: Assembled stacked enclosure layers to evaluate tolerancing and component fit.
[01/05] • 3D Printed Layers: Printed prototype layer frames and to separate components and test fit and tolerancing.

02.2 Custom Sliding Port Covers & ABS Enclosure Fit

Prototyping sliding cover tracks and test-fitting stacked printed frames within the outer ABS protective shell.

• 3D Printed Port Covers: Printed cover prototypes to test fit and alignment around USB and harness ports.
• 3D Printed Port Covers: Printed cover prototypes to test fit and alignment around USB and harness ports.
• 3D Printed Port Covers: Printed cover prototypes to test fit and alignment around USB and harness ports.
• Prototype Testing: Inserted printed layers into ABS enclosure to evaluate fit, alignment, and tolerancing.
• Prototype Testing: Inserted printed layers into ABS enclosure to evaluate fit, alignment, and tolerancing.
[01/05] • 3D Printed Port Covers: Printed cover prototypes to test fit and alignment around USB and harness ports.

02.3 Internal Cable Channeling & Component Trays

Benchtop test routing of flat flex ribbons, power cables, and test signals through dedicated isolation channels in the sub-chassis.

• Wiring & Electronics Layout: Tested wiring paths and electronics placement on printed layers to validate fit.
• Wiring & Electronics Layout: Tested wiring paths and electronics placement on printed layers to validate fit.
• Wiring & Electronics Layout: Tested wiring paths and electronics placement on printed layers to validate fit.
• Wiring & Electronics Layout: Tested wiring paths and electronics placement on printed layers to validate fit.
• Wiring & Electronics Layout: Tested wiring paths and electronics placement on printed layers to validate fit.
• 3D Printed Parts: Printed prototype parts and dremeled enclosures, went through multiple design iterations.
• 3D Printed Parts: Printed prototype parts and dremeled enclosures, went through multiple design iterations.
[01/07] • Wiring & Electronics Layout: Tested wiring paths and electronics placement on printed layers to validate fit.

02.4 Prototype V1 Iteration & Tkinter Software Bring-Up

Initial operational V1 unit with Raspberry Pi 4 running Ubuntu, Tkinter GUI, and Dremeled enclosure ports for functional proof-of-concept.

• Portable Tester v1: Featured LCD screen and hard dremeled USB port cutouts, mainly a prototype design.
• Portable Tester v1: Featured LCD screen and hard dremeled USB port cutouts, mainly a prototype design.
• Portable Tester v1: Featured LCD screen and hard dremeled USB port cutouts, mainly a prototype design.
• Portable Tester v1 Software: Featured a python Tkinter GUI for firmware flashing running on Ubuntu RPI 4.
• Portable Tester v1 Software: Featured a python Tkinter GUI for firmware flashing running on Ubuntu RPI 4.
• Portable Tester v1 Software: Featured a python Tkinter GUI for firmware flashing running on Ubuntu RPI 4.
[01/06] • Portable Tester v1: Featured LCD screen and hard dremeled USB port cutouts, mainly a prototype design.

02.5 Sliding Harness Door & Port Cover Track

Upgrading from rough Dremel cutouts to smooth injection-quality sliding doors with detents for cable harness mating.

• Design Choice: Version 2 added port covers for a cleaner look, upgraded to a glass touchscreen with Raspberry Pi 5, and included an HDMI port to help debug PCBs on the big screen, as the tool is also a computer. Port covers were also added, which solved the issue of hard Dremel cutouts from version 1 (left).
• Design Choice: Version 2 added port covers for a cleaner look, upgraded to a glass touchscreen with Raspberry Pi 5, and included an HDMI port to help debug PCBs on the big screen, as the tool is also a computer. Port covers were also added, which solved the issue of hard Dremel cutouts from version 1 (left).
• Sliding Lid Cover: Replaced rough Dremel cutouts from version 1 with sliding lid track for the harness plug.
• Sliding Lid Cover: Replaced rough Dremel cutouts from version 1 with sliding lid track for the harness plug.
• Sliding Lid Cover: Replaced rough Dremel cutouts from version 1 with sliding lid track for the harness plug.
• Sliding Lid Cover: Replaced rough Dremel cutouts from version 1 with sliding lid track for the harness plug.
[01/06] • Design Choice: Version 2 added port covers for a cleaner look, upgraded to a glass touchscreen with Raspberry Pi 5, and included an HDMI port to help debug PCBs on the big screen, as the tool is also a computer. Port covers were also added, which solved the issue of hard Dremel cutouts from version 1 (left).

02.6 USB Port Cover & Battery Switch Bezel

Precision port covers for USB-A, USB-C, HDMI, and integrated LED battery fuel gauge windows with power toggle switch bezels.

• USB Port Cover: Precise cutouts aligned with the Raspberry Pi 5 ports for a secure fit, while also blocking out debris and dust.
• USB Port Cover: Precise cutouts aligned with the Raspberry Pi 5 ports for a secure fit, while also blocking out debris and dust.
Portable Tester Tool — PROTO
• Battery Cover: The battery cover allowed for a battery LED status indicator and switch cutout.
• Battery Cover: The battery cover allowed for a battery LED status indicator and switch cutout.
• Battery Cover: The battery cover allowed for a battery LED status indicator and switch cutout.
Portable Tester Tool — PROTO
[01/07] • USB Port Cover: Precise cutouts aligned with the Raspberry Pi 5 ports for a secure fit, while also blocking out debris and dust.

02.7 Wire Routing Channel Revisions & Clearances

Internal frame geometry modifications expanding wire path cross-sections to eliminate pinch hazards and reduce cable bend fatigue.

were revised for more wire routing space.
were revised for more wire routing space.
were revised for more wire routing space.
were revised for more wire routing space.
[01/04] were revised for more wire routing space.

02.8 Field-Ready V2 Architecture vs. V1 Benchmark

Side-by-side comparison of the rough V1 prototype versus the sleek, industrial-grade V2 tool featuring Raspberry Pi 5 and Windows 11 compatibility.

• Final V1 & V2 Comparison: V1 is a functional prototype with all core features working, while V2 is a more finalized, field-ready product. The updated version features a cleaner, compact design, additional ports, and upgraded internals including a Raspberry Pi 5 running Windows 11. This allows for faster GUI performance and compatibility with a wider range of Windows-based PCB tools.
• Final V1 & V2 Comparison: V1 is a functional prototype with all core features working, while V2 is a more finalized, field-ready product. The updated version features a cleaner, compact design, additional ports, and upgraded internals including a Raspberry Pi 5 running Windows 11. This allows for faster GUI performance and compatibility with a wider range of Windows-based PCB tools.
[01/02] • Final V1 & V2 Comparison: V1 is a functional prototype with all core features working, while V2 is a more finalized, field-ready product. The updated version features a cleaner, compact design, additional ports, and upgraded internals including a Raspberry Pi 5 running Windows 11. This allows for faster GUI performance and compatibility with a wider range of Windows-based PCB tools.

03Electrical, Firmware & Hardware Integration

Schematic capture, PCB routing, sensor interfacing, actuator control, and embedded firmware implementation.

03.1 Inter-Layer Cable Routing & Signal Separation

Clean routing of power buses, data lines, and debug harnesses through isolated 3D printed frame channels.

• Wire Routing: 3D printed layers include strategic slots for clean wire routing, allowing cables to be layered between sections for a compact and organized design.
• Wire Routing: 3D printed layers include strategic slots for clean wire routing, allowing cables to be layered between sections for a compact and organized design.
[01/02] • Wire Routing: 3D printed layers include strategic slots for clean wire routing, allowing cables to be layered between sections for a compact and organized design.

03.2 Raspberry Pi 5 & 4-Inch Touchscreen Integration

Mounting capacitive glass touchscreen and Raspberry Pi 5 compute engine with active cooling heatsink and HDMI display pass-through.

• Integrated Raspberry Pi & Screen: Mounted a Raspberry Pi with a 4-inch display into the ABS enclosure.
• Integrated Raspberry Pi & Screen: Mounted a Raspberry Pi with a 4-inch display into the ABS enclosure.
• Integrated Raspberry Pi & Screen: Mounted a Raspberry Pi with a 4-inch display into the ABS enclosure.
[01/03] • Integrated Raspberry Pi & Screen: Mounted a Raspberry Pi with a 4-inch display into the ABS enclosure.

03.3 Custom Tester PCB & Direct Harness Soldering

Direct-soldered high-reliability external connector harness onto custom tester board, eliminating intermediate interconnect points.

• PCB Tester Board: Directly soldered the harness connector onto the tester board for less cable connections.
• PCB Tester Board: Directly soldered the harness connector onto the tester board for less cable connections.
• Wire Routing: Mounted the tester board within the 3D printed layers and routed the cables internally.
[01/03] • PCB Tester Board: Directly soldered the harness connector onto the tester board for less cable connections.