AGHAJANlab Long-Range IR Extender for Flipper Zero

A COMPACT DEVICE BUILT FOR GREATER INFRARED RANGE

AGHAJANlab is a student-led electronics brand founded by Vahe Aghajanyan in California. Our goal is to develop original electronics products that solve practical problems while learning and applying the complete product-development process, from an initial idea to a professionally manufactured device.

This project began with a simple observation: although the Flipper Zero includes a useful built-in infrared transmitter, its compact internal emitter has limited range and coverage. It may work well at short distances, but its performance can decrease when the user moves farther away or points the device at an angle.

We wanted to create a compact accessory that gives the Flipper Zero stronger and more dependable infrared transmission without making the setup unnecessarily large or complicated.

PROJECT OVERVIEW

The AGHAJANlab Long-Range IR Extender is a compact hardware accessory designed specifically for the Flipper Zero. It connects to the Flipper Zero and strengthens its infrared transmission, providing greater practical distance and wider coverage than its built-in infrared emitter.

The board contains 12 infrared LEDs arranged to deliver stronger output while keeping the accessory compact and portable. It is intended for legitimate infrared applications, such as controlling and testing televisions, air conditioners and other appliances owned by or authorized for use by the user.

This is an independently developed accessory and is not affiliated with or endorsed by Flipper Devices Inc.

THE PROBLEM

Infrared communication requires a reasonably clear path between the transmitting device and the receiver. The Flipper Zero’s built-in emitter may struggle when used across a large room, at an indirect angle, around reflective surfaces, with receivers that have lower infrared sensitivity or in environments containing strong ambient light.

Increasing the number and coverage of infrared emitters can help create a more dependable signal. However, the final device must remain compact, electrically stable and convenient to use with the Flipper Zero.

Balancing power, portability and reliability is the main design challenge behind this project.

OUR SOLUTION

The AGHAJANlab IR extender connects to the Flipper Zero and receives the infrared transmission signal generated by it. The accessory reproduces that signal through its array of 12 infrared LEDs, extending the Flipper Zero’s practical infrared range and coverage.

The design focuses on:

• Direct compatibility with the Flipper Zero

• Greater range than the built-in infrared emitter

• Wider practical infrared coverage

• Compact and portable dimensions

• Reliable signal reproduction

• A clean and professional physical design

• Convenient connection and operation

The internal circuit and component arrangement are part of the product’s private development. The prototype will allow us to validate its performance without publicly disclosing the complete schematic, component list or manufacturing files.

DEVELOPMENT PROCESS

The project started with research into infrared wavelengths, transmission behavior, LED viewing angles, portable power requirements and the limitations of the Flipper Zero’s built-in infrared transmitter.

After defining the main goals, the PCB was designed and checked for manufacturing issues. Special attention was given to keeping the board compact and arranging the 12 infrared LEDs to provide useful coverage.

The first professionally manufactured version will be used to evaluate the physical design and identify improvements before a later revision. Actual hardware testing can reveal performance and reliability issues that are difficult to predict from digital design files alone.

PROTOTYPE TESTING

Once the prototype has been manufactured and assembled, we plan to test:

• Compatibility with the Flipper Zero’s infrared functions

• Comparison with the Flipper Zero’s built-in transmitter

• Infrared transmission at different distances

• Performance at different angles

• Reliability with compatible infrared-controlled devices

• Power stability during repeated transmissions

• Temperature during extended operation

• Physical durability and connection stability

• Overall portability and ease of use

Testing will be conducted only with devices owned by us or with the owner’s permission. We will document the performance difference between the extender and the Flipper Zero’s built-in infrared transmitter.

The results will guide any changes required for the next revision.

FUTURE PLANS

After testing the first prototype, AGHAJANlab plans to improve the design based on measured performance and real-world use. Possible future improvements include a more compact revision, a protective enclosure, optimized infrared coverage and refinements that make the product easier to manufacture consistently.

This project is also helping us gain experience with professional PCB production, component sourcing, assembly, quality control and the steps required to develop a dependable electronics product.

SPONSORSHIP REQUEST

As a new student-led electronics brand, prototype manufacturing and assembly represent a significant part of our development budget. PCBWay’s support with PCB manufacturing, component sourcing and assembly would allow AGHAJANlab to complete the prototype, perform meaningful testing and continue improving the design.

We will document the completed board, manufacturing quality, assembly, testing process and final performance. PCBWay will be credited for supporting the prototype on the AGHAJANlab website and related project content.

THANK YOU

Thank you to PCBWay for supporting students, makers and independent hardware developers.