10/19/2025 - Platform Research

I spent an hour figuring out the best platform for creating schematic diagram and PCB. i first tried tinkercad but it didn't had Arduino Nano, then I used wokwi and it didn't had IR Sensor. Now I am deciding whether to use KiCad for schematic diagram or just make a handdrawn schematic diagram. I also visited Altium and Proteus for PCB Design and visited JLCPCB website for having an idea PCB manufacturing. I have now decided to first test the robot by making it on breadboard and then shifting to PCB once it works on breadboard.

10/23/2025 - Started making BoM

I spent about 30 Minutes doing research on all the components required for my robot. Then I started choosing the specifications of each componenet that will work best. Then I listed them all in an excel sheet in attempt to create a BoM. Then I did research about the vendors from whom I can get these componenets. There were some like Digilog but they didnt accepted Visa Payment so finally I had to choose AliExpress. Now I am adding all the components to cart on AliExpress and will soon complete the BoM. I hope the next journal will be about completion of BoM and Readme file.

10/28/2025 - Solved a stupid issue

Its something unrealistic to say but I spend 1.5 hours just figuring out which Buck Convertors to use between battery, ESP32 and Motor Driver. Sometimes I found the efficiency to be not suitable and sometimes current, heat, voltage etc. But at the last I have chose 2 different Buck Convertors well suited for their purpose. I also deleted whole BoM and created it once again. Moreover, I tried creating schematic diagram of circuit on KiCad but failed :(. I will do it once BoM is complete.

11/3/2025 - BoM Completed!!!!!

Finally after a lot of time, the BoM is completed. Everything required is now listed along with link and price etc. Now we have started working on schematic diagram. We are currently facing some issues in it as we can't find most of the component symbols in KiCad. I guess we have to now create custom symbols. We hope to ship it by 15-20 November

11/23/2025 - Created Schematic Diagram

After completing BoM, we started making schematic diagram. The issue we faced was that it was our first time doing such thing and first time using KiCad so we don't know how to make schematic.. We figured it out by watching tutorials and with help of ChatGPT. The next problem was that we didnt found the symbols we want. At first, we were worried that we might have to design whole logic of a component to create its custom symbol but then we came to know that creating a symbol is just too easy so we did. Then we spent time figuring perfect voltage for motor encoder and then BOOM!!! Schematic Diagram Completed. Our next goal is to make a PCB. I think it would take us about 15 hours as we are totally null and void regarding PCB.

11/27/2025 - Fixed Schematic Diagram

I have just fixed the whole schematic diagram again. When trying to switch to PCB Creation, I came to know that I should first do ERC Checks. On doing, I got about 40 errors. I tried to solve it all and I did but the schematic diagram became too messy so I have to create a completely new one. Also I have now decided to use ESP32 C6 DevkitM1 instead of ESP32 S3 DevkitC1 because its cheap and fitting for our project. I have also created footprints for all of the components and also added them to PCB. Now I will first design Formula One like Chasis(PCB) and then mount components on it and then I think PCB will be complete.

11/29/2025 - Designed the PCB (Not completed yet)

After I fixed schematic diagram, I imported all the assigned footprints on PCB editor and as told in previous journal that I also fixed all the errors I encountered while importing. The problem was that I didnt had a definite design for the PCB. I didn't knew what to make and how to make. Me and my friend thought a while and presented a simple car shaped design for PCB Shape. We decided few measurements like length, width etc. He advised me to round the corners to make it asthetic (T:T). What I did was designed the PCB Shape on cuts layer and measured so that each side is of perfect length. After that, I had to figure out where to place compoenents on it and it was truly a battle. Literally I designed the whole PCB 3-4 times and each time a component went on wrong place and boom, everything got messed up. But at last I decided to first sketch roughly on paper to find best components placement and it worked. I quickly aligned the compenents as I planned. Then came the routing part. I tried routing but I was failing because sometime 2-3 routes encapsulated a component and there was no chance to kindof connect it. I redesigned routing about 4-5 times and finally now I have the routing. ITS A LOT MESSY!!! I don't care because it was my first PCB design so I just want it to work. Then I ran DRC and got some errors that I fixed. Next I'll kindof place the points where the holes are to be drilled in PCB for components mounting. Then I will recheck it and it will be ready.

12/4/2025 - Done a lot!!!

So I think this is gonna be the last journal. I have successfully completed PCB, routed it. I have also changed the whole design on PCB. After that, I update my BoM trying to minimise the cost as much as possible but its still cost about 160 dollars including PCB and everything. I generated gerber files in Kicad and got a quote of the cost. I added this too to BoM. I uploaded every file to Repository. One thing I want to talk is about taxes. Without taxes, my project would cost about $110 but there are crazy $60 taxes on aliexpress. All I can do now is to hope to get into Tier 2

12/7/2025 - Recreated the BoM

As the cost of project was $160 including each and everything, I got to know that I have to get into Tier 2 to cover this cost and I can't because the effort is not sufficient. So I decided to cut cost. The main problem was that AliExpress was charging $60 AS TAXES.... My all components costed $80 while I just had to pay $60 for taxes. So I decided to turn to a local store for cheaper rates and no taxes. I found one named Digilog. Its authentic and reliable. I went to its website, found all products, added them to cart, created a new .csv file and listed them all with name and cost and qty. Surprisingly, this reduced the whole cost fro $160 to just $70. But the issue I am encountering that is Digilog only supports either Cash on Delievery or Bank Transfer and HCB wont provide this. I have contacted them to solve this issue and I hope that it will be solved somehow. If solved, I could fit into Tier 3.

12/8/2025 - Wrote basic code

So the reviewer demanded to write code for the project even if its basic one so I wrote. The code includes basic functionality of getting input from IR Sensor Array, giving it to ESP32 and then ESP32 gives signal to Motor Driver to adjust speed base on that Input from IR Sensor Array. This journal is quite short one

12/15/2025 - Completed Project for Resubmission

So I now again changed the BoM. Made several changes in it and the cost is now fully approx 100 dollars. I decided to go with n20 motors with encoders because it will ensure smoothness and precision in the car. I also tried to cut several costs including capacitors, battery. For adding a bit more complexity, I have decided to use simple Li-ion battery and integrate a BMS with it. Hope so my project is approved and lands in Tier 3.

12/17/2025 - Made 3D Model

I am sorry I forgot to journal before submitting project. So I made the CAD Model as was demanded by reviewers. I found step files of almost all components except one so i made a simple cad design for that according to its dimensions.

1/20/2026 - NOTE FOR THE REVIEWER

Dear Reviewer,
I have fixed everything now and there's nothing left to do. If you check my journals, you can see that I have worked a lot to reduce cost. It was costing about $170-200 at first but I decided to use local alternatives and finally I reached about $100. Trust me it can't be reduced below this. The decision to use PCB as chassis has been made for lowering weight, adding complexity. The cost with normal chassis will also be same, even if its lower so it will have less complexity so will get in tier 4 while we want complexity and its place in tier 3. Also I have fully fixed PCB, Schematic Diagram and 3D Model after the updated BoM. Readme has been fixed and everything is alright now. I have also added the competition in ReadMe in which I plan to participate via this robot. If you check the website given, it clearly says that the competition is planned on 11-13 June. My O Level exams are starting soon and will end on June 10 and I will quit my laptop and all other activities on 1 March so I have very few time. I hope this project is approved this time and as soon as possible. Please (T-T)

2/9/2026 - Fixed the whole Project

So I have fixed the whole project as asked by reviewer. I have used Global Labels in Schematic Diagram and also realised I was missing a power switch that I have now. Also I updated the whole PCB accordingly and fixed all DRC errors etc. Its looking good. I also updated the PCB in the 3D Model and created new Gerber files for it. Its ready to reship! Hopefully it don't get in queue for 20 days again.

2/15/2026 - Rechecked the whole Project

So I have rechecked the whole project in accordance with the submission deadline. Here is what I concluded.
It is Original with CAD Files, Untested Firmware.
It has been Sanity Checked by: https://hackclub.enterprise.slack.com/team/U08AZBA9NFJ and in KiCad Discord Server also.
BoM is present in .csv Format with all Links and Prices alongwith PCB Source Files (Gerbers, Schematic, Board etc). It's completely Organised and Readable
The ReadMe file has description of what the project is, why I made this and how to use the project, contains 2 Pictures of 3D Model, 2 Pictures of PCB, 1 Picture of Schematic Diagram, BoM in Table form at end with Links etc
It has no AI Usage. I have fixed several things in readme, CAD etc. I also have fixed PCB by removing all 90 degree turns etc.

The step file was a bit bigger than maximum size limit so I have to use Git LFS but unfortunately it messed all up... my whole project vanished so I have to spend a lot of time fixing that... finally i have fixed that and now the project is complete