6 layers31.8 × 27 mm
4 layers71 × 51.5 mm
WLED Controller
GreatMesa/Bike-Led-ControllerCustom LED Bike Ring & Controller PCB
- Size
- 71 × 51.5 mm
- Copper layers
- 4
- Thickness
- 1.6 mm
- Parts
- 69
- Nets
- 86
- Pads
- 328
- Tracks, vias
- 520, 111
- Pours
- 7
- Routed
- Yes
- KiCad
- KiCad 10.0 (file 20260206)
- Created
- 1 Jan 2026
- Updated
- 18 Jun 2026
Overview
WLED Controller is an open-source printed circuit board by GreatMesa, from the GreatMesa/Bike-Led-Controller repository on GitHub. It is a 4-layer board of 71 × 51.5 mm with 69 parts on 86 nets, routed with 520 tracks and 111 vias.
It is built around the ESP32-WROOM-32E, INA236AIDDFR and TPS566238RQFR, with the BMI270, SN74LVC2T45DCURE4 and USBLC6-2P6 among its other parts. Its parts include 21 resistors, 20 capacitors, 9 ICs, 3 transistors and 3 connectors. It belongs with the ESP32 boards of this library.
Main components
6
ESP32-WROOM-32E
SMD,18x25.5mmSMD,18x25.5mm WiFi Modules ROHSEspressif SystemsWiFi Modules
INA236AIDDFR
TSOT-23-8-300mV~48V -40℃~+125℃ 1.7V~5.5V 100pA 150dB 1uV 25nV/℃ 300uA High-side detection、Low-side detection、Power monitoring、Programmable threshold alarm、Integrated ADC、Enable/shutdown function ±26V TSOT-23-8 Current Sense Amplifiers ROHSTexas InstrumentsPower Management - Specialized
TPS566238RQFR
VQFN-9-HR(1.5x2)-40℃~+125℃@(TJ) 1 3V~18V 50uA 600kHz 600mV~7V 6A Adjustable Buck Built-in Overcurrent Protection、Output discharge、Adjustable soft-start、Operating status indication、Cycle-by-cycle current limiting Step-down type Yes VQFN-9-HR(1.5x2) DC-DC Converters ROHSTexas InstrumentsDC-DC Converters
BMI270
LGA-14(2.5x3)-40℃~+85℃ 1.71V~3.6V 16bit 2KB 3.5uA Accelerometer Gyroscope SPI、I2C X,Y,Z X,Y,Z ±16g ±2000dps LGA-14(2.5x3) Accelerometers ROHSBosch SensortecAccelerometers
SN74LVC2T45DCURE4
VSSOP-832mA 32mA Level translator Power-off protection、Output enable high-impedance VSSOP-8 Translators, Level Shifters ROHSTexas InstrumentsTranslators, Level Shifters
USBLC6-2P6
SOT-666-6-40℃~+125℃ 150nA 17V 2 3.5pF 5.25V 5A@8/20us 6V ESD IEC 61000-4-2 Unidirectional SOT-666-6 ESD and Surge Protection (TVS/ESD) ROHSSTMicroelectronicsESD And Surge Protection (TVS/ESD)
README
README.mdBike LED Controller
This project is sponsored by JLCPCB
Introduction
The goal of this project is to add more customizability to bike lights. When I was looking though lights for my bike I found that there was a limited amount of colors and patterns I could use. I wanted to create lights and controllers so I could have a better understanding of what was going on in the controller in terms of current consumption and speed of the bike, things that also were not present in other controllers. In this project, I designed a custom bike ring + a custom led controller board so that I could have a greater level of control.
Custom LED Ring
For the ring, I decided to split the base and top of the ring into 8 seperate segments. This was due to the size of the ring being way to big for my bike & in terms of the print time & assembely ease, 8 segments seemed to do the best in those 2 categories.
For the bottom, in order to connect the segments together, I decided to designed them so they would have a insert slot + a segment that goes into it. For the top, I ended up coating it in a layer of FLEX-SEAL in order to act as a water reppelent + a diffusior once I sanded it down to a degree. Here is one fully assmebled ring in action:
LED Ring GIF
Custom LED Controller
For the LED contoller, I had multiple goals in mine. The main goal I had was the ability for the contoller to convert a higher voltage input to a stable 5V. To do this, I used the TPS566238RQFR buck converter to convert the input voltage (designed for 2S) into 5V. I also used a AMS1117 to convert the 5V supply into 3.3V for the digital IC's and the ESP32. Speaking of digital IC's, I used 5 in this design, a INA236 to meausre the voltage, current, & power output of the controller, a TMP117 to measure the tempature of the board / enclousre enviroment, a BMI270 to measure the speed of the bike for custom effects, a SN74LVC2T45DCUR to convert the ESP32's 3.3V logic into a usable 5V logic level for the LED, and last but not least the CP2102N to allow communication between the USB pherephial and the ESP32 via UART. Here are the schematics, PCB layouts, & the 3D view.
Schematic
PCB Layout
3D View
Parts
69| Qty | Value | Footprint | References |
|---|---|---|---|
| 9 | 100nF | Capacitor_SMD:C_0402_1005Metric | C3, C10, C11, C15, C16, C17, C18, C20, C21 |
| 6 | 10k | Resistor_SMD:R_0402_1005Metric | R1, R3, R11, R17, R19, R20 |
| 6 | 4.7k | Resistor_SMD:R_0402_1005Metric | R12, R13, R14, R15, R18, R21 |
| 3 | NPN | Custom-Footprints:SOT95P240X115-3N | Q1, Q2, Q3 |
| 2 | 10uF | Capacitor_SMD:C_0805_2012Metric | C8, C9 |
| 2 | 22 | Resistor_SMD:R_0402_1005Metric | R6, R7 |
| 2 | 22uF | Capacitor_SMD:C_1206_3216Metric | C1, C2 |
| 2 | 4.7uF | Capacitor_SMD:C_0603_1608Metric | C13, C19 |
| 2 | 47uF | Capacitor_SMD:C_1210_3225Metric | C4, C5 |
| 2 | 5.1k | Resistor_SMD:R_0402_1005Metric | R8, R9 |
| 2 | Conn_01x03 | TerminalBlock_Phoenix:TerminalBlock_Phoenix_MKDS-1,5-3_1x03_P5.00mm_Horizontal | J2, J4 |
| 1 | 0.01 | Resistor_SMD:R_2512_6332Metric | R5 |
| 1 | 10k | Resistor_SMD:R_0603_1608Metric | R16 |
| 1 | 10nF | Capacitor_SMD:C_0402_1005Metric | C7 |
| 1 | 10uF | Capacitor_SMD:C_0603_1608Metric | C22 |
| 1 | 1k | Resistor_SMD:R_0402_1005Metric | R10 |
| 1 | 1uF | Capacitor_SMD:C_0402_1005Metric | C6 |
| 1 | 2.2uF | Inductor_SMD:L_Coilcraft_XAL6030-XXX | L1 |
| 1 | 220k | Resistor_SMD:R_0402_1005Metric | R2 |
| 1 | 30k | Resistor_SMD:R_0402_1005Metric | R4 |
| 1 | AP1117-33 | Package_TO_SOT_SMD:SOT-223-3_TabPin2 | U3 |
| 1 | BMI270 | Package_LGA:Bosch_LGA-14_3x2.5mm_P0.5mm | IC5 |
| 1 | Boot Switch | Button_Switch_SMD:SW_SPST_TS-1088-xR025 | BOOT |
| 1 | Buzzer | Custom-Footprints:CMI97050380SMTTR | BZ1 |
| 1 | CP2102N-Axx-xQFN28 | Package_DFN_QFN:QFN-28-1EP_5x5mm_P0.5mm_EP3.35x3.35mm | IC4 |
| 1 | D_Schottky | Diode_SMD:D_0603_1608Metric | D5 |
| 1 | ESP32-WROOM-32E | Custom-Footprints:ESP32-WROOM-32E | U2 |
| 1 | Enable Switch | Button_Switch_SMD:SW_SPST_TS-1088-xR025 | EN |
| 1 | INA236AIDDFR | Custom-Footprints:SOP65P280X110-8N | IC1 |
| 1 | LED | LED_SMD:LED_0603_1608Metric | D2 |
| 1 | LOGO | Custom-Footprints:feet pics | G*** |
| 1 | M1 | MountingHole:MountingHole_3.2mm_M3_Pad_Via | H1 |
| 1 | M2 | MountingHole:MountingHole_3.2mm_M3_Pad_Via | H2 |
| 1 | M3 | MountingHole:MountingHole_3.2mm_M3_Pad_Via | H3 |
| 1 | M4 | MountingHole:MountingHole_3.2mm_M3_Pad_Via | H4 |
| 1 | SN74LVC2T45DCUR | Package_SO:VSSOP-8_2.3x2mm_P0.5mm | IC3 |
| 1 | TMP117xxDRV | Package_SON:WSON-6-1EP_2x2mm_P0.65mm_EP1x1.6mm | IC2 |
| 1 | TPS566238RQFR | Custom-Footprints:TPS566238RQFR | U1 |
| 1 | UART | Connector_PinSocket_2.54mm:PinSocket_1x04_P2.54mm_Vertical | UART |
| 1 | USBLC6-2P6 | Package_TO_SOT_SMD:SOT-666 | U4 |
| 1 | USB_C_Receptacle_USB2.0_14P | Connector_USB:USB_C_Receptacle_GCT_USB4105-xx-A_16P_TopMnt_Horizontal | J3 |
| 1 | XT-60 | Connector_AMASS:AMASS_XT60-F_1x02_P7.20mm_Vertical | BAT1 |
Questions
How big is the WLED Controller PCB?
It measures 71 × 51.5 mm and has 4 copper layers, 1.6 mm thick.
What parts does the WLED Controller use?
69 parts, built around the ESP32-WROOM-32E, INA236AIDDFR, TPS566238RQFR and BMI270. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.
Where can I download the WLED Controller KiCad files?
From the GreatMesa/Bike-Led-Controller repository on GitHub, at the commit this page was made from: the board is Hardware/WLED Controller.kicad_pcb and its schematic Hardware/Microcontroller.kicad_sch. PCBKit opens the board in the browser, with nothing to install.
Can I use the WLED Controller design in my own project?
Its repository states no licence, so its author keeps all rights: ask GreatMesa before reusing the design.
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