Acoustics · Embedded Control
High-Intensity Diversionary Alert Device
Overview
Developed a reusable non-pyrotechnic diversionary device capable of generating synchronized high-intensity visual and acoustic stimuli using high-power LEDs and a piezoelectric sound system. The project focused heavily on acoustic chamber optimization, embedded control, and manufacturable mechanical design.
The engineering challenge
Design a compact, reusable diversionary device capable of producing intense visual and audible effects without pyrotechnics while maintaining safety, manufacturability, and battery-powered operation.
Confidential Prototype
Diversionary Alert Device — proprietary prototype; imagery withheld at the client's request.
- Controller
- ESP32
- Driver
- DRV8662 piezo driver
- Outputs
- High-power piezo · High-power red & green LEDs
- Development Software
- Fusion 360 · ESP-IDF
What I owned
- Designed and optimized the acoustic chamber geometry
- Supported PCB integration and system architecture
- Developed embedded firmware for synchronized operation
- Optimized piezo driver performance
- Conducted acoustic testing and sound characterization
- Improved mechanical design for manufacturability
- Evaluated and validated multiple prototype iterations
System architecture
Full technical specification
- Controller
- ESP32
- Driver
- DRV8662 piezo driver
- Outputs
- High-power piezoHigh-power red & green LEDs
- Development Software
- Fusion 360ESP-IDF
- Programming
- Embedded C
- Test Equipment
- OscilloscopeSound level meter3D printing equipment
Development process
- 01Requirements Definition
- 02Acoustic System Design
- 03Electronic Design
- 04PCB Development
- 05Firmware Development
- 06Acoustic Testing
- 07Mechanical Optimization
- 08Prototype Validation
Engineering challenges
- Maximizing sound pressure level (SPL) while maintaining efficiency
- Optimizing acoustic chamber geometry and resonance
- Tuning piezo operating frequencies
- Improving driver efficiency and thermal performance
- Designing for injection molding and manufacturability
- Balancing acoustic performance with mechanical constraints
Skills demonstrated
Outcome
Successfully developed a non-pyrotechnic prototype capable of producing approximately 130 dB synchronized with high-intensity red and green LED signaling while meeting manufacturability requirements.