Personal project · PCB design

Custom Drone Flight Controller PCB

MCUSTM32F405EDAKiCadFIRMWAREBetaflightIMUBosch BMI270POWERTPS5450FLASHGD25Q16E
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Assembled Board

System implementation

MCUSTM32F405RGT6 (168MHz Cortex-M4 with FPU), running custom Betaflight target ETHANF405 with motor 4 remapped to PB5 (TIM3_CH2) to prevent DMA1 Stream 3 collisions
Power TreeTPS5450DDAR buck converter (VBAT to 5V/5A) with Panasonic POSCAP 220µF ESR-matched output cap; dual-LDO architecture (AP2112K for logic/VDDIO, TLV733P for dedicated quiet IMU VDD)
IMUBosch BMI270 6-axis MEMS gyro/accelerometer on isolated 3.3V sensor rail, mounted at the center of the board

Overview

A flight controller for an FPV quad, built around an STM32F405 and running Betaflight on a custom target (ETHANF405). There are two 3.3 V LDOs: an AP2112K for the logic and a TLV733P that feeds only the IMU, so switching noise from the MCU never reaches the gyro. That split paid off when the 426xx IMU I designed around went out of stock. Swapping to a Bosch BMI270 meant a new footprint and new decoupling caps, and nothing in the power tree had to change. The ESC I paired it with (a Flycolor Raptor BLS-04) has no BEC, so the board makes its own 5 V at up to 5 A from the 4S pack with a TPS5450 buck. It also has SPI flash for blackbox logs, an i-BUS input for a FlySky FS-iA6B receiver, and solder jumpers that keep each power stage disconnected until I close them on the bench.

Hardware and telemetry

BlackboxGigaDevice GD25Q16E, 2 MB of SPI NOR flash for blackbox logs. The BOM called for the 16 MB BY25Q128ES and the wrong part got ordered, so logging runs at a 1/4 sample rate to fit about 87 seconds per log
Bring-UpNormally-open solder jumpers split the power tree across 4 stages for current-limited bench testing; test points on all rails and scope ground loops
PCB & Fab~60×60mm 4-layer stackup (ENIG finish for LGA gyro) with single-sided SMD layout for hotplate reflow; mated to Flycolor Raptor BLS-04 ESC via 10-pin JST SH1.0 harness
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