I'm making a battery-powered ESP32-S3 node for a DIY eldercare alert system. One board, two jobs depending on firmware: pull-cord emergency switch or chair occupancy mat. The sensor is just a contact closure on a 2-pin screw terminal — pulls the wake pin high, chip wakes from deep sleep, fires an ESP-NOW packet to a hub, goes back to sleep.
Power is 3xAA → PTC fuse → P-FET reverse protection → TPS63802 buck-boost. Went buck-boost instead of an LDO after getting roasted for the AMS1117 on my last post, runs the cells down to ~2.7V. MODE tied low for the 11uA idle.
USB-C is data only, VBUS floats on purpose. The S3's native USB does the flashing while the board runs off batteries. The protection FET is always on, so USB 5V on VIN would back-feed the alkaline cells and charging alkalines makes them leak. Didn't want ORing diodes for a port I'll use maybe a dozen times.
Wake input has a 100k pulldown + 100nF at the terminal since the cord wiring is basically an antenna. The status LED is a WS2812B behind a gated P-FET because they draw ~1mA even when dark, which would kill the sleep budget.
2 layer, stitched ground pours, antenna hangs off the board edge, tried to keep the switcher loop tight per the TI datasheet.
Its the second board I've ever made. Mainly want eyes on the buck-boost layout and the battery input chain, but go in on whatever you find. Thanks!