This project started as a “quick build” and somehow turned into a full redesign loop I did not see coming.
I spent around 16 hours straight building it end to end. No breaks, just flow. Schematic → PCB → Fusion 360 enclosure. Everything was moving fast and honestly felt solid at the time.
⚡ Schematic phase
Mapped out the full switch matrix. Rows and columns looked clean on paper. Nothing felt off. This was the calm stage.
🧩 PCB design
Routed everything around the XIAO RP2040. Tight layout, all pins assigned, everything looked correct.
That’s the keyword: looked.
🖼️ Fusion 360 enclosure
Built the case, aligned the board, checked fitment. At this point I genuinely thought:
“yeah, this is a first-try success.”
It wasn’t.
💥 The moment it broke
During final checks, I realized something stupid but critical:
✔ Rows were connected
❌ Columns were NOT connected to the XIAO
At first I thought: “ok easy fix, PCB edit, done in 2 minutes.”
Then reality hit.
🚫 The real problem
No GPIO pins left on the XIAO.
Zero. Everything was already assigned.
So the “quick fix” wasn’t possible at all.
🔧 Forced redesign
Only option left was to free up pins.
That meant removing the potentiometer I had already designed into the system.
And that one change didn’t stay small:
~ PCB had to be updated again 🔁
~ Pin mapping had to be redone 🧠
~ Fusion enclosure had to be redesigned 🧱
~ Mechanical layout shifted again 📐
What should’ve been a tiny wiring fix turned into a full system rollback.