Ultra-compact wearable device with a 4+2 rigid-flex PCB, ESP32, and MPU6050 sensor to track jaw motion and communicate via Bluetooth.
3D model will load when visible
Drag to rotate · Scroll to zoom · Interactive 3D model
Fitting a fully functional jaw-motion tracking system into an AirPod-like form factor (20mm × 17.2mm, under 12g) required a 4+2 rigid-flex PCB to accommodate the ESP32 module, IMU sensor, antenna, and Li-ion battery in a single compact structure. Maintaining reliable Bluetooth connectivity with a custom 2.4GHz antenna on minimal ground plane area was a key RF design challenge, as was achieving a comfortable ear-worn fit while keeping the assembly robust enough for repeated daily use.
A lightweight, ear-worn device weighing only 12g, designed to track jaw movements and communicate with a companion mobile app over Bluetooth. The system uses a 4+2 rigid-flex PCB measuring just 20mm x 17.2mm, integrating an ESP32 microcontroller, MPU6050 motion sensor, custom antenna, and rechargeable battery. Developed with ESP-IDF and Embedded C, the device was programmed via JTAG and designed to fit within a form factor similar to modern wireless earbuds.
| Microcontroller | ESP32 |
| Motion Sensor | MPU6050 (6-axis IMU) |
| PCB Type | 4+2 rigid-flex |
| PCB Dimensions | 20mm × 17.2mm |
| Connectivity | Bluetooth Low Energy (2.4 GHz) |
| Firmware SDK | ESP-IDF |
| Programming | JTAG |
| Power | Rechargeable Li-ion battery |
| Weight | 12g |
| Form Factor | Ear-worn, AirPod-like |
Whether it's a compact wearable, an industrial controller, or a connected IoT device — let's discuss your hardware requirements.