ESP-LED-03: Wide Voltage Audio-Reactive WLED Controller (5–24V)
ESP-LED-03 adds a single DD4012SA component so the controller can drive 5–24V LED strips while keeping the same compact 40mm width (PCB length increased to 77mm).
This is a small upgrade to the ESP-LED series: ESP-LED-03 keeps the same feature set you already know from v1/v2 (ESP32-S3 SuperMini, INMP441 audio, light sensor, reliable level shifting for data lines) and adds exactly one component - the DD4012SA - which lets the board safely drive higher-voltage LED strips (5–24V).
The goal was simple: enable compatibility with 12V and 24V LED strips (common WS2811/WS2815 style) without adding complexity to the assembly or significantly changing the board layout. To make room for the additional voltage handling parts the PCB length was increased to 77mm while the width remains 40mm.
What the DD4012SA does #
The DD4012SA is used here as a compact, high-voltage buck converter, allowing the board to safely operate with LED strips powered from 5V up to 24V without putting the ESP or its peripherals at risk. Instead of redesigning the entire power stage, integrating the DD4012SA provides a simple, reversible upgrade that maintains compatibility with existing designs.
🆕 New Component: DD4012SA
The key component that enables 5-24V LED strip compatibility
In practice it means:
- Native support for 5V/12V/24V LED strips (such as WS2811, WS2815, and similar) while preserving compatibility with standard WLED firmware and pinout conventions.
- The ESP and logic circuitry are still powered from a regulated 5V rail (onboard or external). Only the LED output path is routed through the DD4012SA and associated protection parts.
- Minimal changes: one additional component to place, and a slightly longer PCB.
WARNING - VOLTAGE COMPATIBILITY #
WARNING - VOLTAGE COMPATIBILITY: If you power the board with a 12V or 24V supply, make absolutely sure the LED strip you connect is rated for that exact voltage. Do NOT connect a 5V LED strip to a 12V/24V supply - this will damage the strip instantly and may cause hazards.
PCB changes #
To accommodate the DD4012SA, the board length was increased to 77mm. Everything else - connectors, terminal blocks, and the 40mm width - remains the same as ESP-LED-02 so the board still fits existing enclosures designed for the earlier versions with a little extra room.
The extra parts are intentionally placed close to the LED terminal to keep high-current traces short and to reduce noise coupling into the logic section. Power traces for the LED output were widened and routed to keep heating minimal under heavy loads.
WLED and wiring #
WLED configuration stays the same as ESP-LED-02. The LED Data pin and all sensor pins remain unchanged from ESP-LED-02. The only wiring difference is that the 3-pin LED terminal now can accomodate a higher-voltage LED supply (5–24V) on the V+ pin; GND stays common with the controller. The data pin remains routed through the 74AHCT125N (or equivalent) level shifter to keep signal integrity for the LED input.
A couple of safety reminders:
- When powering the board with 12V or 24V supplies, make absolutely sure you are using LED strips rated for that voltage (do NOT connect a 5V strip to a 12V/24V supply).
- Use proper gauge wiring for the LED supply when running higher voltages and longer strips.
- Verify the diode and protection parts are correctly oriented before powering up.
BOM #
Only one item is added/changed compared to ESP-LED-02 - the DD4012SA for wide voltage support. Everything else in the BOM remains the same as ESP-LED-02.
Quick pricing summary:
- Parts-only cost: 8.01 EUR (excluding PCB)
- Total per assembled board: 9.28 EUR (including PCBWay per-PCB share)
Visual Parts List with Purchase Links #
| Color | Image | Name | Description | Purchase Link |
|---|---|---|---|---|
| 🟢 |  | PCB | Freshly manufactured ESP-LED-03 PCB (ordered from PCBWay) | PCBWay Project Link |
| 🔵 |  | ESP32-S3 SuperMini | Main controller, dual-core ESP32-S3 with USB support |  |
| 🟣 |  | INMP441 MEMS Microphone | Digital MEMS mic breakout for clean, noise-free I2S sound input |   |
| 🟠 |  | 74AHCT125N | Logic level shifter to bump 3.3V data up to 5V for addressable LEDs | |
| ⚪ |  | Light Sensor (LDR5516) | Connects to an analog GPIO input, with a pull-down resistor to ensure a clean, stable reading when idle | |
| 🔴 |  | 2-pin Terminal Block | Power input connection | |
| 🔴 | | 3-pin Terminal Block | LED strip output (V+, Data, GND) - now supports 5-24V | |
| ⚫ |  | Big Electrolytic Capacitor | 470uF or similar, rated for 6.3V or higher, stabilizes power | |
| 🟡 |  | Reverse Voltage Protection Diode | Diode capable of handling up to 5A (e.g., SR260) | |
| 🟤 |  | Series Data Resistor | 330–470 ohms, protects the first LED pixel from signal spikes | |
| 🟤 | | Pull-Down Resistor for Light Sensor | 10kΩ resistor connected between LDR and ground | |
| 🟩 |  | Infrared Sensor | TSOP38238 or Similar | |
| 🟦 |  | Male Header Pins | 2 x 7, 2 x 3, 3 x 2 or 26 Pins Total | |
| 🆕 | | DD4012SA 5V | Wide voltage MOSFET driver - NEW in ESP-LED-03 | |
Optional Accessories #
| Color | Image | Name | Description | Purchase Link |
|---|---|---|---|---|
 | Infrared Controller | 44-pin or Other IR Controller | |
Cost Breakdown (Detailed) #
| Name | Quantity | Price | Unit Price |
|---|---|---|---|
| PCB | 1 | 1.23 EUR | 1.23 EUR |
| ESP32-S3 Super Mini | 1 | 3.59 EUR | 3.59 EUR |
| INMP441 | 1 | 1.79 EUR | 1.79 EUR |
| 74AHCT125N | 1 | 0.24 EUR | 0.24 EUR |
| LDR5516 | 1 | 0.14 EUR | 0.14 EUR |
| 2-pin Terminal Block | 1 | 0.09 EUR | 0.09 EUR |
| 3-pin Terminal Block | 1 | 0.12 EUR | 0.12 EUR |
| Electrolytic Capacitor 470uF | 1 | 0.08 EUR | 0.08 EUR |
| SR260 | 1 | 0.12 EUR | 0.12 EUR |
| Resistors (2x) | 2 | 0.02 EUR | 0.04 EUR |
| TSOP38238 | 1 | 0.49 EUR | 0.49 EUR |
| Header Pins | 1 set | 0.16 EUR | 0.16 EUR |
| DD4012SA | 1 | 1.19 EUR | 1.21 EUR |
TOTAL: 9.28 EUR
I paid for the PCB order on PCBWay 14.35 USD (≈ 12.31 EUR) including shipping, which makes 1 PCB cost around 1.23 EUR. With the rest of the parts calculated, the total cost per assembled board comes to 9.28 EUR (this includes the per-PCB share of the PCBWay order). The parts-only subtotal (excluding PCB) is 8.01 EUR.
Ordering and files #
If you'd like to order PCBs for ESP-LED-03, the project is available on PCBWay just like the previous versions. You can order the board directly from the PCBWay project page.
👉 Quick Link: ESP-LED-03 PCBWay Project
How to order on PCBWay (quick steps):
- Click the project link above to open the PCBWay project page.
- Review gerber previews and manufacturing options (board thickness, solder mask color, surface finish).
- Select quantity (e.g., 10) and any extras (stencil, panelization if you want multiple boards per panel).
- Add to cart and proceed to checkout. Enter shipping details and choose a shipping method.
- Upload any modifications if you made local changes; otherwise use the provided Gerbers.
- Place the order and keep an eye on the project page for production updates.
Conclusion #
ESP-LED-03 is a small, focused upgrade that brings wide-voltage LED compatibility to the ESP-LED family with a single additional component (the DD4012SA) and minimal PCB changes. It keeps the same audio-reactive and auto-brightness features while allowing you to use common 12V and 24V LED strips.
Key takeaways:
- The board length is increased to 77mm; width remains 40mm so most existing enclosures still work.
- The parts-only cost (excluding PCB) is 8.01 EUR, and the total per assembled board (including PCBWay per-board share) is 9.28 EUR.
- Safety first: if you power the board with 12V or 24V, only use LED strips rated for that voltage - mixing voltages will damage the strip and can be dangerous.