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