Nexara – Edge-AI Animatronic Physical Avatar Head

Nexus AI Core is an air-gapped physical AI avatar head engineered for real-time edge awareness, multi-axis spatial tracking, and expressive visual feedback without relying on cloud APIs.

Hardware Architecture:

Visual HUD: Dual 1.28" Round IPS LCDs for dynamic 60 FPS eye graphics, telemetry, and system readouts.

3-DOF Neck Actuation: High-torque digital bus servos providing full pan, tilt, and roll head dynamics.

Vision Subsystem: Embedded spatial camera module for local optical tracking and depth mapping.

Power Management: Custom power distribution PCB with dedicated 12V-to-5V step-down rails to isolate high-current servos from sensitive logic lines.

Build Objective:

To construct a production-grade, multi-axis physical head interface that bridges local LLM inferencing with dynamic, real-world mechanical response.

WHO I AM:

Founder & Lead Architect at Nexus AI Core (Pty) Ltd based in South Africa, specializing in full-stack, air-gapped physical AI systems and edge hardware architectures.

PROJECT DESCRIPTION:

A full physical build log and schematic breakdown for a multi-axis edge AI avatar head. The project combines 3D-printed enclosure structures, isolated servo power rails, dual IPS circular displays, and local vision processing into a single off-grid robotics chassis.

WORDS TO PCBWAY (SPONSORSHIP REQUEST):

We are seeking PCBWay sponsorship to cover custom PCB fabrication, component assembly, and 3D printing for the avatar chassis. In return, PCBWay branding, logos, and direct links will be prominently featured across our video build demonstrations, technical documentation

n, and social build logs.

1. Short Overview & Vision

Nexara is an autonomous, physical animatronic head engineered as an embodied human-computer interaction (HCI) interface for local, offline AI architectures. Powered by the Nexus AI Core framework—which encompasses over 30 specialized local open-weight models and the Nexus Nova orchestration engine—Nexara translates offline LLM outputs, visual vision processing, and persona telemetry into real-time physical expression, fluid head movement, visual display feedback, and audio responses with zero reliance on cloud services.

2. Technical Architecture & Component Matrix

Single-Carrier SMT Assembly (Custom PCBA)

Processing Unit: Surface-mounted ESP32-S3-WROOM-1 MCU running local serial/I2C telemetry bridges from the primary Python host engine.

Motion Driver Core: Integrated PCA9685PW SMT 16-Channel 12-Bit PWM driver with ESD protection.

Power Regulation Plane: Embedded 5V/10A Synchronous Buck Step-Down Regulator with LC thermal/ripple filtering to isolate dynamic servo draw from logic rails.

Audio Subsystem: MAX98357A I2S Digital Audio Amp IC driving dual 3W 4\Omega micro-speakers for direct, noise-free local voice output.

Visual Display Array: Dual 1.3" SPI IPS Color Displays (240x240) for high-FPS animated eye matrix rendering.

Actuation & Physical Chassis

Primary Neck Axes: Heavy-duty TD-8120MG 20kg coreless digital servo handling pitch and yaw loads.

Secondary Articulation: Micro-servos driving internal eye/visor mechanisms.

Vision Sensor: Top-mounted HD auto-focus vision module feeding real-time frame pipelines back to local vision models.

Structural Shell: High-precision SLA 3D-printed internal skeleton frame housing internal electronics, camera mounts, display sockets, and neck pivot joints.

3. PCBWay Support Request

To transition from a functional breadboard setup to an integrated unit, we request full sponsorship covering:

Turn-key SMT PCB Assembly (PCBA): 5 units of our consolidated custom power/logic carrier board.

SLA 3D Printing / Mechanical Fabrication: Custom high-precision resin printing for internal structural chassis brackets and facial frame components.

4. Deliverables & Sponsorship Visibility

In exchange for manufacturing support, we will provide:

Multi-Platform Showcase: Dedicated video logs and posts across YouTube, LinkedIn, and social channels showcasing the custom PCBA, SLA enclosure, and assembly process, explicitly crediting PCBWay.

Open-Source Community Hub Post: Complete KiCad schematics, Gerber files, BOM, and 3D STEP models published directly on the PCBWay Community Hub with direct service links.