Jigs and fixtures
ESP32 AIO Flight Controller Assembly
- Bounding box
- 32.0 × 34.0 × 10.1 mm
- Engine
- Precision B-rep
- Parameters
- 33
- Published
- August 22, 2026
Download
Free to download and use. See the terms.
The prompt
Design a compact all-in-one (AIO) flight controller for an RC fixed-wing aircraft based on an ESP32, with full compatibility with Betaflight. Requirements * MCU: ESP32, specifically a variant that is actually supported by the chosen/current Betaflight version * Battery: 3S LiPo, 9.0–12.6 V * Motor: 1× brushless motor * ESC: integrated ESC with at least 30 A continuous current, preferably 40 A for additional headroom * Servos: 3 independent PWM servo outputs * Flight controller firmware: Betaflight-compatible * Mixer: Betaflight AIRPLANE mixer * Outputs: 1× motor/ESC + 3× servo * BEC: integrated 5 V BEC for powering the servos, with sufficient current capacity for 3 servos * Receiver: support for CRSF/ExpressLRS and SBUS * ESC telemetry: support if possible * USB: USB-C for Betaflight configuration and firmware flashing * OSD: include if supported by the selected MCU and Betaflight * Size: as compact as reasonably possible, ideally around 30 × 30 mm or smaller * Power protection: reverse-polarity protection, voltage-spike protection and appropriate filtering * ESC cooling: sufficient copper area and PCB traces for at least 30 A continuous current Required deliverables 1. Complete electrical schematic 2. Complete BOM with specific component part numbers 3. ESP32 pinout 4. Exact PWM/timer assignment for the motor and all 3 servos 5. Complete 30–40 A ESC circuit 6. Complete 5 V BEC circuit 7. ELRS/CRSF receiver connection 8. USB-C circuit 9. Betaflight configuration, including resource mapping and the AIRPLANE mixer 10. PCB recommendations including layer count, trace widths and copper thickness 11. Power distribution and grounding recommendations 12. Thermal calculations for the ESC and BEC 13. A complete pinout table for all connectors and test points Critical compatibility requirement Do not select an ESP32 simply because it is an ESP32. First determine which specific ESP32 variant/MCU is genuinely compatible with the current Betaflight firmware architecture and has the required hardware peripherals, including hardware timers/PWM outputs, UARTs, SPI, USB and sufficient processing/RAM resources. If a standard ESP32 is not suitable for running Betaflight directly, identify the closest compatible ESP32 variant or explain what would need to be changed in Betaflight to support it. Do not assume that Betaflight support exists. Verify the compatibility before designing the hardware. The final design should be realistic and manufacturable using standard PCB assembly services and readily available components.
Parameters
| Name | Value | Range |
|---|---|---|
| PCB size (square) | 30 mm | 20 – 50 |
| PCB thickness | 1.6 mm | 0.8 – 2.4 |
| ESP32 module width | 18 mm | 10 – 30 |
| ESP32 module length | 25.5 mm | 15 – 40 |
| ESP32 module height | 3 mm | 1 – 5 |
| ESP32 antenna overhang | 4 mm | 0 – 15 |
| ESC power stage length | 20 mm | 10 – 30 |
| ESC power stage width | 15 mm | 5 – 30 |
| ESC power stage height | 3 mm | 1 – 10 |
| BEC length | 12 mm | 5 – 20 |
| BEC width | 10 mm | 5 – 20 |
| BEC height | 2.2 mm | 1 – 6 |
| USB-C width | 8.4 mm | 6 – 12 |
| USB-C depth | 7.3 mm | 5 – 12 |
| USB-C height | 3.2 mm | 1.5 – 5 |
| XT30 width | 14 mm | 8 – 20 |
| XT30 depth | 12 mm | 8 – 18 |
| XT30 height | 7 mm | 3 – 12 |
| Servo header width | 2.54 mm | 1.5 – 5 |
| Servo header depth | 7.62 mm | 5 – 12 |
| Servo header height | 8.5 mm | 3 – 12 |
| Motor pad length | 8 mm | 5 – 12 |
| Motor pad width | 6 mm | 3 – 10 |
| Motor pad height | 0.5 mm | 0.2 – 2 |
| Receiver width | 6 mm | 4 – 10 |
| Receiver depth | 4 mm | 3 – 8 |
| Receiver height | 2 mm | 1 – 5 |
| Shunt length | 6.4 mm | 3 – 10 |
| Shunt width | 3.2 mm | 1.5 – 6 |
| Shunt height | 0.8 mm | 0.5 – 2 |
| Protection length | 8 mm | 4 – 12 |
| Protection width | 5 mm | 3 – 10 |
| Protection height | 2 mm | 1 – 5 |
Every value above is a live dimension. Open a model like this in the editor and each one becomes a slider you can drag before exporting.
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