EEG CAR-01 RevB routed

EEG Field Kit — Design & Production Package v2.4

TI One Voice research programme — one.witysk.org, Brussels, Belgium Board revision B · 2 September 2026

The complete manufacturing package for EEG-CAR-01 Rev B: a battery-powered, 16-channel EEG headset built around an ESP32-S3 carrier board, together with the helmet and enclosure, the electrode harness, the firmware, the production test programme and fixtures, and all the packing, quality and regulatory documentation needed to produce the finished kit — flight case included.

The package is designed so that a manufacturer can quote, review and build from it directly: the Gerbers, drill files, netlist, BOM and CPL files are included, along with every printed part, the assembly work instructions and an end-to-end test programme that runs from Chrome over USB. For the study itself — participants, collaborators, grant bodies and funders — see one.witysk.org/studies.

Status at a glance

Nothing in this package has been manufactured or measured. No board has been fabricated, no part has been printed, no firmware has been flashed to silicon, and no electrode has touched a person. Every performance figure is calculated, and each is labelled as calculated where it appears.

Read KNOWN_ISSUES.txt before quoting or building anything. It is the short list, in one place, of what is wrong with the data as shipped — 6 open items and 22 unapproved assumptions in 15 sections. Everything in it is also in the controlled documents; the file exists so that problems are found here rather than at CAM time.

Orientation — read in this order

1. README_package_index.txt + KNOWN_ISSUES.txt — the orientation pair. The index says what every folder is for and gives the rebuild commands (its header is stale at v2.2; this package is v2.4).
2. docs/RFQ-EEG-001 Rev E — the actual request: numbered requirements (E-, S-, F-, T-), the pricing template, and §9.4's correction-iteration terms for prototypes that arrive not working.
3. docs/DSN-EEG-003 Rev D — the governing document. Architecture, the carrier board, and the precedence rules that decide which document wins when two disagree.

Precedence: DSN-EEG-003 Rev D > RFQ-EEG-001 Rev E > ICD-EEG-006 > SCH-EEG-005 > DSN-EEG-002 > PARTS-EEG-019 > RUL-EEG-021 > the bidder BOM. Where a number appears in a document and in tools/design.py, design.py governs — tools/emit_all.py regenerates every fabrication file from it in one pass, so the package cannot drift.

Repository layout

The board

EEG-CAR-01 Rev B — 150.0 × 130.0 mm, four layers (L1 signal, L2/L3 reference planes split AGND_REF/DGND, L4 signal), 30 connectors, 211 reference designators, 156 nets.

• 3,745 track segments, 552 through vias, 0 duplicates
• 145 of 145 nets one connected copper island; 0 DRC violations
• Smallest clearance 0.260 mm, narrowest conductor 0.200 mm, smallest plated hole 0.300 mm
• No digital net in the analogue zone; exactly one AGND_REF-to-DGND bridge and one HARN_SHIELD-to-DGND bridge

The layout was produced by the programme's own constraint-aware autorouter and verified by measurement on the finished polygons — but it has not been reviewed by a human layout engineer. The DRC report lists every one of the 169 relaxed connections so a reviewer can go straight to the places that need attention.

Firmware

ESP-IDF v5.2.5, target esp32s3, Phase 1 configuration (secure boot off). Four release images with SHA-256 checksums, a 920-line main.c with 16 host commands and 13 provisioning opcodes, drivers for the ES8388 codec, SDMMC, ATECC608B, MAX17048 gauge and the envelope onset detector.

It has never run on silicon, and no hardware exists. The SPI timing, every ADS1299 register value, USB enumeration and the whole analogue front end are assumptions no silicon has answered. F-08 (block signing) is unimplemented; the ATECC608B config template is only 4 of 128 bytes reviewed — that write is irreversible, so it gates on a real part.

Testing & quality

• TST-EEG-004 Rev C — the per-unit test: 32 steps T00–T30, with a 5,033-line JSON Schema and a stdlib-only validator so any two vendors emit the same record file.
• JIG-EEG-009 Rev C + fixtures/ — four test fixtures as buildable data, with RP2040 controller firmware passing 154 host checks.
• TOOL-EEG-022 — the browser connectivity test (webtest/EEG-Connectivity-Test.html) and the interop harness that keeps firmware and protocol from drifting apart.
• SIM-EEG-018 — a production simulation that walks one unit through all fifteen stations, purchase order to refurbishment: 193 passed, 0 failed, 6 open.
• ECO-EEG-016 — the change register that owns the document namespace and explains why everything is the way it is.

Rebuilding the package from source

python3 tools/run_build.py          # route, pour, check            (~20 min)
python3 tools/emit_all.py --cached  # Gerbers, drawings, schematic
python3 tools/emit_extras.py        # spec sheet, netreport, STEP, manifest
python3 tools/mech_gen.py           # STL and STEP for every printed part
python3 tools/mech_drawings.py      # dimensioned drawings and renders
python3 tools/emit_workbooks.py     # the three spreadsheets
python3 tools/simulate_production.py --report docs/SIM-EEG-018_....md
python3 tools/make_docs.py          # A4 .docx and .pdf of every document

python3 tools/check_consistency.py  # cross-document consistency gate
python3 webtest/build.py            # rebuild the single-file connectivity tester
node webtest/tests/*.mjs            # protocol tests
sh webtest/tests/interop/run.sh     # firmware-vs-protocol interop (57 checks)

Production phases

1. Phase 1 — 2 prototypes
2. Phase 2 — 10 kits
3. Phase 3 — 10 to 40 further kits (25 to 50 total)

Sponsorship

This study is run by a non-profit and funded by donations and grants that have not yet all been secured. Any part of the work treated as sponsorship — a discounted prototype build, parts at cost, donated units — is welcome, in return for named credit in the published open-hardware design files, acknowledgement in the resulting papers and on the platform, and the case study of an instrument you built being used in a pre-registered study.

Licence & contact

Hardware and documents: CC BY-SA 4.0 · Firmware: MIT

Third-party datasheets are excluded from both grants. Manufacturer datasheets and other third-party documents referenced by this package remain the property of their respective manufacturers, are referenced or redistributed for reference only, and are not covered by the CC BY-SA 4.0 licence above. See docs/datasheets/README_datasheets.md for the index and docs/datasheets/third_party/LICENCE_NOTE.md for the terms.

Stephane van der Aa — Founder, TI One Voice one.witysk.org · stephane@stepvda.com · +32 493 70 16 01