Objective

A miniaturized wearable (30×30 mm) 6-layer HDI (High Density) biotelemetry PCB aimed at clinical-grade data acquisition. It combines a 24-bit ECG, IMU, discrete optical SpO2 & HR, and BLE streaming, utilizing an STM32 MCU and a heavily isolated mixed-signal power architecture to eliminate crosstalk.

Key Features:
Analog & Mixed-Signal Front End
  • 24-bit delta-sigma ADC with biopotential AFE integrated with bottom-layer exposed ENIG dry electrodes for 2-channel ECG acquisition.

  • A discrete SpO₂ analog front end, Maxim MAX86141, for pulse oximetry

  • The IMU tracks the patient's exact physical movement in real-time, allowing the MCU to mathematically subtract motion-induced noise from the sensitive ECG and SpO₂ signals while providing info on the user's physical state like waking, running, resting, etc.

Filtering
  • High CMRR (100+) biopotential AFE to reject common mode noise

  • Digital Notch filter to remove 60Hz AC hum

  • Hardware LPF with common mode cut-off frequency of 19.74KHz and a differential cut-off of 9.87KHz on ECG electrodes to filter RF noise

  • Digital LPF of 40 Hz cut-off frequency to remove EMG noise in ECG signals

  • Active RLD (Right Leg Drive) and low PGA (To prevent saturation) to remove dry electrode DC offset and Common mode noise from ECG

Power Management
  • A high-end PMIC specifically designed for wearables - Maxim MAX77654 SIMO PMIC

  • Specifications of PMIC are a 1S LiPo BMS and charger, 2 buck rails, 1 boost rail and 1 ultra-low noise LDO

  • Buck-LDO cascade for biopotential AFE for stable and low noise power rail

PCB Design

  • Targeting 30mm * 30 mm 6-layer high-density PCB

  • Using packages like BGA, VGA, QFN, etc. as much as possible for space efficiency.

  • Using small sizes like 0201 for passives

  • Stackup target - At least two internal GND planes, GND pours on rest of the layers, one power plane and three SIG layers

  • Noise reduction techniques such as via shielding, proper return path tracking and physical isolation of Analog/Digital/Power/RF sections