This is a speedrun first pass. Here's what we'd want to answer before anyone orders a board or cuts a mould.
BoardRouted and clean, but never built
The two-layer board passes ERC and DRC with nothing left unconnected, after we widened it to 54 mm to give the autorouter room. Nobody has ordered or soldered one yet. The first prototype has to confirm the AM312's pin order, the mic hole lining up with the face port, and the fit on the enclosure's posts.
VoiceFree-form speech needs a bigger chip
Whisper-style speech-to-text is out of reach on this board, because even Whisper-tiny needs more RAM than the S3 has. A wake word plus fixed commands covers "snooze", "done" and "I drank water". One of our hosts reports running Whisper on an ESP32-P4 dev board, which we haven't reproduced yet. That's the upgrade path, but the P4 has no Wi-Fi, so it needs an ESP32-C6 alongside it. That means a bigger board, a slightly bigger head and more power.
FeelCan you feel the breeze at arm's length?
3010 blowers move very little air. We need to test whether it's noticeable at 50–70 cm on a low, quiet duty cycle. If it isn't, the fix is a 40 mm axial fan and a bigger head.
SensingDoes the PIR see a still, seated gamer?
PIRs detect movement, and a focused player barely moves. The field of view also needs testing from 50–80 cm, with the user sitting below the sensor's axis.
PowerStaying under 500 mA
Peak draw can pass what a PC's USB 2.0 port allows. The firmware has to take turns between loads, and we haven't measured real currents yet.
ProductHow do parents set it up?
The schedule, the phrases and the volume all need a setup flow. That could be a phone page over Wi-Fi or USB. None of it is designed yet, and it has to work without cloud accounts.
ProductWill a 14-year-old keep it plugged in?
It has to be annoying enough to work and charming enough not to end up in a drawer. Snooze limits, a "streak" reward and the tone of the voice lines are all untested.
MechanicalFastening, ears and the mic seal
The face cap and rear shell need screw bosses or snaps. The solid ears need coring out for moulding, and the rubber boot between the mic and the face port is a guess.
ElectricalNo ESD or fuse on USB yet
A kid's desk is a hostile place. Add a USBLC6 and a PTC fuse, re-terminate the blower's lead to JST-SH, and confirm the AM312's pin order and the mic's stock.
DrawingThe GA drawing lags the model
Rev A shows a 25 mm blower, a 23 mm speaker and an INMP441 mic. The model and board moved to a 3010 blower, a 28 mm speaker and the ICS-43434. The drawing needs a rev B.