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1Validate the sensor first
Before designing any PCB, prove your detection method works with the real object in the real environment. We spent three days on this and it saved us weeks.
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2Pick an MCU for your power budget, not your feature list
The nRF52840 was right because idle current mattered more than WiFi.
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3Structure firmware around tasks from day one
Zephyr's threading model kept the sensor loop deterministic even while BLE was active.
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4Design the PCB with test points
We added pads on every power rail and the I2C lines — worth the small board space cost.
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5Print the enclosure early
Physical fit problems surface fast and cheaply in 3D prints
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6Test on battery, not USB
Power behavior changes completely once you're running off a LiPo.
Himanshu Dada
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