Overview

This project explores the design of a folded flexible PCB that can be seamlessly embedded inside industrial cables. The goal was to create a compact and durable module capable of adding wireless connectivity, USB communication, and smart control features directly into cable assemblies without increasing their external footprint.

By leveraging a thin and bendable board, the module integrates smoothly inside the cable jacket, making it ideal for industrial environments where space optimization, robustness, and reliability are essential.

Key Features

• Wireless Connectivity – Powered by the ESP32-U4WDH, the system supports Wi-Fi and Bluetooth communication for remote monitoring, control, or data transmission.
• USB Interface – A modern USB-C connector (TYPE-C-31-M-12) paired with the CP2102N bridge ensures simple PC connectivity for configuration, debugging, and firmware updates.
• Voltage Level Shifting – The BSS138 MOSFET provides reliable bidirectional logic level translation between different system voltages.
• Efficient Power Management – The LM3281YFQR delivers stable regulation for low-power operation and LED signaling.
• Embedded Design – Built on a flexible PCB, the entire circuit folds neatly into the cable structure, ensuring rugged integration without adding bulk.

Components Used

• ESP32-U4WDH – Dual-core MCU with Wi-Fi + Bluetooth connectivity
• CP2102N-A02-GQFN20 – USB-to-UART bridge for easy programming and communication
• TYPE-C-31-M-12 – Compact USB-C connector
• BSS138 – Logic-level bidirectional MOSFET
• LM3281YFQR – Power management component

Applications

This embedded module can be applied in several fields:

• Industrial cable assemblies with integrated wireless monitoring
• Smart retrofitting of legacy equipment
• Secure sensor data transmission within harsh environments
• Cable diagnostics and maintenance with USB + wireless access

Outcome

The project demonstrates how electronics can be invisibly integrated into cables, paving the way for smarter industrial systems. The use of flexible PCB technology allows the circuit to withstand bending and stress while maintaining performance, making it a practical solution for next-generation industrial connectivity.