This week I focused on refining the physical design and improving hardware reliability, with the goal of preparing the system for a clean and stable demo-ready build.
Housing Design and 3D Modeling
A major focus this week was designing the enclosure for the LumiKey system:
- Created a 3D model of the housing to contain the ESP32, wiring, LED chain, and FSR circuitry
- Iterated on dimensions to ensure proper alignment with piano keys and internal component spacing
- Considered accessibility for wiring, maintenance, and future modifications
This step is important for transitioning from an exposed prototype to a more polished and portable system.
Hardware Debugging and Signal Stability
I worked on identifying and resolving reliability issues in the hardware:
- Discovered that loose “hair-like” wires and exposed connections were causing intermittent LED failures and unstable behavior
- Re-soldered and reinforced connections to eliminate unintended contact between power, ground, and data lines
- Improved insulation and organization to reduce noise and prevent future short circuits
These fixes significantly improved overall system stability, especially during movement and handling.
FSR Calibration and Threshold Tuning
Another key area this week was refining how the FSR sensors behave when integrated with the piano:
- Adjusted threshold values to account for how FSR strips respond when placed under real piano keys
- Observed differences between free-space testing and actual mounted conditions
- Tuned press and release thresholds to reduce false positives and improve responsiveness
This ensures that the system accurately detects user input in realistic playing conditions.
Material Selection for FSR Interface
I also experimented with different materials placed on top of the FSR strips:
- Tested materials such as foam, cardboard, and thin rigid paper layers
Evaluated based on force distribution, sensitivity, and consistency of readings - Selected a thin cardboard-like material as it provided the best balance between responsiveness and stability
This layer plays a critical role in translating key presses into reliable sensor readings.
Next Steps
– Finalize and fabricate the enclosure design
– Integrate all components into the housing for full system assembly
– Continue long-duration testing for hardware reliability
– Validate system performance during continuous piano interaction