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We found what broke the AirLeak Pro prototypes

My engineer and I tracked it down: a bad footprint on the board, most likely from a file that got corrupted on its way to the manufacturer. We’re finishing the report now, then we order the new devices and start shipping as soon as possible. The 18 December 2026 ceiling still stands.

Good news on the AirLeak Pro pre-orders: we found the problem.

Update, 12 October 2026. My engineer and I identified what went wrong with the prototypes. It was a bad footprint on the board: the copper pads for a part didn’t match the part. The design we validated was correct, so our best guess is that the file got corrupted somewhere on its way to the manufacturer.

That matters, because it means the redesign itself holds up. Schematics, layout and simulation were right; what came back from production simply wasn’t built from the file we checked. Cleaner switch, straightforward USB path, pin mapping unchanged: all of that stays.

Right now we’re finalizing the written report on exactly what happened. As soon as it’s done, we order the new devices. When they arrive they go straight through the bench tests, and shipping starts immediately: first paid, first shipped.

For context: on 18 September I wrote that the prototypes had come back non-functional and that I couldn’t give a hard ETA. I committed to a working device by 18 December 2026 as the ceiling, not the target. That ceiling still stands, and now that the cause is known I want to beat it. You’ll hear it on this page and in Discord before anywhere else.

Your pre-order is safe. Nothing is canceled, nothing is re-queued, and the price you paid still stands. Thank you for your patience through all of this. If the wait has become too long for you, message me and we’ll sort it out personally, refund included.

And please — if you have any question at all, don’t hesitate to write to us. About the board, about what we’re seeing on the bench, about your order, anything. I would much rather hear from you than have you sitting there wondering.

Where we are now

The cause is found. What’s left is execution: finish the report, order the corrected devices, test them, ship. The ceiling is unchanged.

Ceiling: 18 December 2026

  1. 01

    Diagnosing what went wrong

    Done: cause found

    A bad footprint on the board, most likely from a file that got corrupted on its way to the manufacturer. The design we validated was right; the boards that came back weren’t built from it.

  2. 02

    Finish the report, order the new devices

    Where we are right now

    We’re finalizing the written report on what happened. As soon as it’s done, we order the new devices with the correct footprint. I would rather do this properly once than ship a run of half-working devices.

  3. 03

    Test the new devices

    Same days they arrive

    Charging and voltage tests, heating and thermal behavior, buttons and switch abuse, case fit across four printers. Nothing leaves my desk until it survives this.

  4. 04

    Assembly and shipping

    Immediately after testing

    Cases are printed in parallel — two printers on my side, two on my friend’s — and I assemble everything by hand. Shipping starts right away: first paid, first shipped.

What I test before anything ships

  • Charging and voltage tests
  • Heating and thermal behavior
  • Buttons and switch abuse testing
  • Case fit across four printers

The redesign, for the record

The fault was a footprint in the file production received, not the redesign. None of this work is thrown away: this is the board that ships, pin mapping and compatibility with the previous design intact.

  • The switch

    No more switch sticking out of the enclosure. It sits flush and is properly supported by the case, and flashing is simpler because of it.

  • Battery charger

    The battery charging circuit was updated accordingly.

  • USB / ESP32

    The previous mux-based approach was replaced with a USB hub. The ESP32 connects directly to a PC, and two COM ports are exposed.

  • A new engineer

    Someone new joined on the hardware side, and the new revision went through their hands end to end.

  • The case

    A fresh 3D design built around the new board, printed in-house on four printers so the enclosure is not what holds up shipping.

  • Board compatibility

    Connector positions, pin mapping, the ESP32-S3 and the ESP32-C5 all remain unchanged, so compatibility with the previous design is maintained.

Questions you probably have

Ask me on Discord

Do I need to do anything?

No. Your order stays exactly as it is. You don’t need to re-order, re-pay, or contact anyone to keep your place in the queue.

Are you giving up on the AirLeak Pro?

No. Not now, not later. The device is happening. We found the cause (a bad footprint, most likely from a corrupted file sent to the manufacturer) and we’re moving straight on to the corrected devices.

What actually broke?

A bad footprint: the copper pads for a part on the board didn’t match the part. The design we validated in schematics, layout and simulation was correct, so our best guess is that the file got corrupted on its way to the manufacturer. We’re finishing a written report on it now.

Do you have an ETA?

Not a hard date yet. It depends on how fast the new devices are produced and delivered once we order them, and I won’t invent one. The ceiling I committed to on 18 September 2026 still stands: a working device by 18 December 2026. With the cause found I want to beat it, and you’ll hear it here and in Discord first.

Which revision will I get?

The new one, at the price you already paid. No upgrade fee, no separate early-buyer version.

Where do I get updates?

This page and the Discord. If anything moves — good or bad — I post it in both rather than going quiet.

What if I don’t want to wait?

Message me on Discord and we’ll sort it out personally, refund included if that’s what you need. I would rather you tell me than sit there frustrated.

Can I ask you a question directly?

Please do. If anything on this page is unclear, or you want more detail on what we’re seeing on the bench, don’t hesitate to reach out. I would much rather hear from you than have you wondering.

Your pre-order is safe. Talk to me any time.

Nothing is canceled and nothing is re-queued. Existing pre-orders ship first, first paid first shipped, at the price you already paid. If the wait has become too long, or you just want to ask what we’re seeing on the bench, message me — I’d rather hear from you than have you wondering.